Drill cuttings conveyance systems and methods

ABSTRACT

Vessels, system and methods for conveying drilling cuttings material, which, in certain aspects, include a system for conveying material from a vessel, the system having a vessel for receiving material to be conveyed, a first conduit for conveying air, a second conduit for receiving air from the first conduit and for conveying air into the vessel, a metering screw for receiving material from the vessel and for moving the material from the vessel, a discharge line for receiving the material from the metering screw, the discharge line having an exit end, pressure sensor apparatus for sensing pressure in the discharge line, and control apparatus for automatically controlling the metering screw in response to a pressure sensed by the pressure sensor apparatus.

RELATED APPLICATION

This is a continuation-in-part of U.S. application Ser. No. 10/392,285filed Mar. 19, 2003, now U.S. Pat. No. 6,936,092 Ser. No. 10/764,825filed Jan. 26, 2004, now U.S. Pat. No. 6,988,567 and Ser. No. 10/875,083filed Jun. 22, 2004 now U.S. Pat. No. 7,195,084 all of whichapplications are incorporated fully herein for all purposes and from allof which the present invention claims priority under the Patent Laws.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed to the movement of drilled cuttings(wet, damp, or dry), to the positive pressure pneumatic transport ofsuch drilled cuttings solids, and, in particular aspects, to themovement of oilfield drilled cuttings or other solids for disposal,onward transportation, storage or further processing.

2. Description of Related Art

The prior art discloses various methods for the positive pressurepneumatic continuous pneumatic transport of low slurry density and lowparticle density dry solids and non-continuous high slurry densitytransport of high particle density wet material. Many low densityslurries typically have particles mixed with air with a specific gravityless than 1.0. The prior art discloses various methods that employ thevacuum transport of high particle and low particle density solids.

To drill an oil or gas well, a drill bit at the end of a drill string isrotated to drill the borehole in the earth. A drilling fluid (“drillingmud”) pumped through the drill string to the drill bit lubricates thedrill bit and carries drilled cuttings produced and other solids anddebris to the surface through an annulus between the drill string'sexterior and the borehole's interior. Due to its expense, attempts aremade to recover and re-use the used drilling mud. Solids are removedfrom the drilling mud by, e.g. vibratory separators, such as those shaleshakers disclosed in U.S. Pat. No. 5,265,730, WO 96/33792 and WO98/16328. Recovered drilling mud is received in a reservoir orreceptacle beneath a shale shaker and separated solids (e.g. drilledcuttings) move off the top of the shaker's screens into a ditch,receptacle, or skip.

Drilled cuttings having processed by a shale shaker can containapproximately 10% to 20% moisture (oil, water) by weight.

It is now often desirable and/or legislatively required to transportrecovered drilled cuttings to a processing site on shore to removesubstantially all of the oil and contaminates therein so that thedrilled cuttings can be disposed of or used in an environmentally safeand friendly way. Environmental agencies around the world are movingtowards a “zero discharge” policy from offshore rigs. Continuousdrilling on an offshore oil rig is common and drilled cuttings arestored on the rigs until they can be transported by ships known assupply boats which collect the oily drill cuttings and take them toanother site for further processing. There is a need to efficiently andeffectively store the oily drilled cuttings on the rig and also a needto efficiently and effectively store the cuttings on supply boats.

In certain prior art systems oily drill cuttings are loaded intovessels, skips or cuttings boxes which are lifted by a crane onto asupply boat.

U.S. Pat. No. 6,702,539 issued Mar. 9, 2004, PCT publication number WO00/76889 and European Patent No. EP 1,187,783 B1 disclose systems fortransporting drill cuttings in the form of a non-free flowing paste, thesystem comprising a pressure vessel having a conical hopper dischargeportion having a cone angle sufficient to induce mass flow. The drillcuttings are stored on a rig and supply boat in ISO sized storagevessels which have a conical hopper discharge portion, such that the ISOsized container vessels can be discharged between each other on the rigand ship and between the ship and port.

German Patent No. DE 40 10 676 discloses an apparatus for conveyingsewage sludge or concrete. The apparatus comprises a pressure vesselhaving a feed opening and a screw conveyor therebelow. Paddles act as astirrer and forcibly fill the screw conveyor through an opening in thepressure vessel. The sewage sludge or concrete is moved by the screwconveyor into a nozzle into which compressed air is applied to move thesewage sludge or concrete along a pipe in a continuous stream

United Kingdom Patent No. GB-A-2,330,600 discloses a system fortransporting oil drill cuttings from a rig to shore. The systemcomprises the steps of mixing the oily drill cuttings with a mud to forma slurry, storing the slurry in retention tanks on the rig andsubsequently pumping the slurry to retention tanks on a ship fortransportation to shore.

There has long been a need, recognized by the present inventors, forcontinuous positive pressure pneumatic transport of low slurry density,high particle density material, and in certain aspects, oilfield drilledcuttings (wet, damp, or dry) or other oily/wet waste material. There haslong been a need, recognized by the present inventors, for such systemswhich occupy relatively little space.

SUMMARY OF THE PRESENT INVENTION

The present invention, in certain aspects, discloses a system forprocessing drilling cuttings material, the system having: a cuttingsdosing system for receiving drilling cuttings material from a wellboreoperation and selectively dosing it to adjacent apparatus.

The present invention, in certain aspects, discloses a vessel forselectively holding drilling cuttings material, the vessel having: abody, the body having a hollow container with an interior space forreceiving drilling cuttings material and from which drilling cuttingsmaterial may exit from the body; a first opening through which thedrilling cuttings material is introducible into the hollow container; asecond opening through which the drilling cuttings material is passableout from the hollow container; movement apparatus, the movementapparatus having a movement member within the hollow container andmovable adjacent the second opening to facilitate passage of thedrilling cuttings material into the second opening; and an exit openingthrough the body through which drilling cuttings can exit from thehollow container.

The present invention, in certain aspects, discloses a vessel forselectively holding drilling cuttings material, the vessel having: abody, the body having a hollow container with an interior space forreceiving drilling cuttings material and from which drilling cuttingsmaterial may exit from the body; a first opening through which thedrilling cuttings material is introducible into the hollow container; asecond opening through which the drilling cuttings material is passableout from the hollow container; movement apparatus, the movementapparatus having a movement member within the hollow container andmovable adjacent the second opening to facilitate passage of thedrilling cuttings material into the second opening; an inlet in the bodythrough which compressed gas under pressure is flowable into the body tofacilitate the passage of the drilling cuttings material through thebody; the movement apparatus further having power apparatus connected tothe movement member for moving the movement member; wherein the secondopening has a length and the movement member has an elongated memberwith a length substantially equal to the length of the second opening;wherein the second opening has a width and the movement member ismovable back and forth across said width; conveyance apparatus locatedbelow the second opening, the conveyance apparatus including a conduitfor receiving the drilling cuttings material passing through the secondopening.

The present invention, in certain aspects, discloses a system forprocessing drilling cuttings material, the system having: a cuttingsfeeder system for receiving drilling cuttings material from a wellboreoperation; conduit apparatus for conveying drilling cuttings materialfrom the cuttings feeder system to first storage apparatus and to secondstorage apparatus; sensor apparatus for sensing moisture content ofdrilling cuttings material in the cuttings feeder system; valveapparatus on the conduit apparatus for selectively controlling flow tothe first storage apparatus and to the second storage apparatus; controlapparatus in controlling communication with the cuttings feeder system,the sensor apparatus, and the valve apparatus for selectively permittingflow of drilling cuttings material from the cuttings feeder system andthrough the conduit apparatus to either the first storage apparatus orthe second storage apparatus depending on sensed moisture content of thedrilling cuttings material sensed by the sensor apparatus; and thecontrol system permitting flow to the first storage apparatus whensensed moisture content is below a pre-selected valve and to the secondstorage apparatus when sensed moisture content is above the pre-selectedvalve.

The present invention, in certain aspects, provides a vessel which, inone aspect is a drill cuttings storage vessel with a pressure vessel, apneumatic fluid inlet for introducing pneumatic fluid under pressure,and a discharge opening. The storage vessel has a base through which thedischarge opening is located and at least one member within the vesselslidable over and along the base towards and away from the dischargeopening for facilitating movement of the drill cuttings towards thedischarge opening. With appropriately shaped edges and/or members on theslidable member, the slidable member digs material from above it anddelivers the material to conveyor apparatus below the discharge opening;and, in one particular aspect, in this manner a conveyor line ismaintained substantially full thereby facilitating consistent dosingrates. The conveying line may, in certain aspects, be dosed with drillcuttings in such a way that the conveying line is full so that the drillcuttings move along the conveying line in one long slug. Alternatively,the drill cuttings may form a plurality of slugs along the conveyingline separated by pockets of pneumatic fluid. This is controlled by therate at which the drilled cuttings are released or pushed into theconveying line, which is known as the “dosing rate”. The dosing rate isdictated by, among other things, the consistency of the drilledcuttings, the pneumatic pressure applied to the drilled cuttings, andthe diameter of the conveying line in order to achieve a predeterminedconveying rate. In a preferred embodiment, a conveying rate of thirtymetric tons of drilled cuttings per hour are moved along from thestorage vessel into the conveying line and on to a destination.

The drill cuttings stored in the storage vessel may be dry or may bewet. Wet cuttings contain water and/or oil. Wet drill cuttings may befree flowing, non-free flowing, or pasty. Drill cuttings are often wetafter having been processed with shale shakers. The drill cuttings maybe dried by a vortex dryer, as described herein to produce substantiallydry drill cuttings which, in some aspects, may be free flowing solidswhich abide by the laws of Newtonian flow.

In certain aspects the sliding member has a chamfered edge or edges forsliding under the drill cuttings and/or advantageously a scooping edgefor scooping the drill cuttings into the opening. In certain aspects,the scooping edge has a planar surface at right angles to the base.

In certain aspects the storage vessel has a piston and cylinder assemblymoving the sliding member(s) for sliding the sliding member(s) over thebase towards the discharge opening. Alternatively, a rack and pinionsystem may be employed or a rotating disk having an arm located on theperimeter thereof to translate rotational motion into forwards andbackwards motion, in a similar way to a crank in a car engine. Such asliding member may be used in a variety of tanks, including, but notlimited to, a mass flow hopper, core flow hopper, flat bottom hopper, achisel plane flow-type tank, or a conical tank.

In certain aspects a storage vessel according to the present inventionhas a second member slidable over the base towards and away from thedischarge opening for moving the drill cuttings towards the dischargeopening. In one aspect the second member is fixed to the first memberand forms a frame. In certain embodiments the storage vessel has a screwconveyor located at the discharge opening to facilitate movement ofcuttings out of and away from the storage vessel. In one aspect a box islocated at a discharge end of the screw conveyor and the box has a lowerchamber with a discharge port for connection to a flow line. The box mayhave a pneumatic fluid inlet (in one aspect, into the lower chamber) forsupplying pressurized pneumatic fluid (e.g. air, nitrogen or anotherinert gas) and a pneumatic fluid inlet may be substantially in line withthe discharge port. In certain aspects, the screw conveyor has a secondblade or blades near the discharge end of the screw conveyor forbreaking up and distributing the drill cuttings. In one particularaspect, the screw conveyor has a plurality of radially extending fingersfor breaking up and distributing the drill cuttings.

The base of the storage vessel may be conical, planar, or substantiallyhorizontal. By using a non-conical hopper or vessel in certainembodiments according to the present invention, bridging is inhibitedand reduces as compared to bridging that can occur in certain conicalvessels. In one aspect, the sliding member(s) is/are substantially flatfor sliding over a planar base. In certain aspects the sliding member isrigid.

In certain embodiments a storage vessel according to the presentinvention is skid mounted. In certain embodiments a storage vesselaccording to the present invention has a capacity of between five andtwenty cubic meters; and, in one aspect between ten and fifteen cubicmeters; and in one particular aspect twelve cubic meters. In certainaspects a vessel according to the present invention has a circular base,which, in some embodiments is between 1.5 and 4 meters in diameter, andin one particular embodiment is 2.7 meters in diameter.

In various systems according to the present invention a drill cuttingsstorage vessel according to the present invention is fed using a blowtank.

In certain embodiments, the present invention provides methods forstoring and handling drill cuttings, the method including: receivingdrill cuttings in a pressure vessel; applying pneumatic fluid underpressure to the drill cuttings in the pressure vessel; and using amovable member to facilitate movement of the drill cuttings towards adischarge opening in the pressure vessel. In one aspect such a methodaccording to the present invention includes discharging the drillcuttings into a screw conveyor; and, in a particular embodiment,includes discharging the drill cuttings from the screw conveyor into abox, whereupon a pneumatic fluid under pressure is applied to the drillcuttings to move the drill cuttings along a flow line.

In certain aspects of systems according to the present invention, apump, e.g. a positive displacement pump or a cement pump (or pumps) areused in addition to or in place of blow tank(s) to move the drillcuttings, e.g. from shakers or a ditch or vortex dryer to the storagevessels. The floor area and overall space around shale shakers is oftenlimited and so the storage vessels or skips for containing the drillcuttings are often placed relatively far, e.g. a few hundred feet, fromthe shale shakers.

Many prior art systems use a cuttings dryer which, when coupled with apneumatic cuttings conveying system reduces waste volumes and liquidcontent, leading to an overall reduction in storage volume required andtransportation and disposal costs are also reduced. Due to driedcuttings tending more towards lead phase when using a positive pressurepneumatic conveying system, it is important in certain aspects that anychange in dryer output is acted upon at the earliest opportunity. It isknown to be problematic to convey a product when its consistency is notuniform. To have a storage tank with a mixture of dried cuttings and wetcuttings can require a conveying system to alternate between variousmodes of flow, between continuous and discontinuous phase flow. The flowregime of cuttings within a pipe does not lend itself to this change aswet cuttings tend towards dense phase with either a shearing type orplug type flow whereby the slugs of cuttings act as a pulsatileregular/irregular moving bed which may fill the entire cross section ofpipe; and dried cuttings tend towards suspended flow. The transfer rateis required to be substantially reduced should this “mixture” of modesof flow transfer be required. Reduced transfer rates are not desirablewhile a vessel is alongside a rig taking on a load. In order to maximizetransfer rates, it is beneficial to maintain a cuttings consistencywithin the storage vessel.

The cuttings discharge from a dryer with a screen may be significantlyaltered should the screen “blind,” hence not allowing the liquid to passthrough resulting in a wet discharge. This is known to happen onoccasions when a change in drilled formation results in a change ofparticle size generated at the drill bit.

In certain systems according to the present invention a wetness meter isused to continuously monitor dryer discharge. The wetness meter may bebased on the Near Infrared (NIR) principle, where it is known thatseveral molecular bonds absorb infrared light at well definedwavelengths. Common bonds are O—H in water, C—H in organics and oils andN—H in proteins. The light absorbance level at these specificwavelengths is proportional to the quantity of that constituent in thesample material. Infrared filters within the instrument sensor generatea sequence of light pulses, one of these pulses is selected to be at thespecific absorbance wavelength for the constituent required to bemeasured while the other pulses are selected so as to determine thereflectance properties of the material. The light pulses illuminate thesample being measured with the reflected light being collected andfocused onto a detector, the electrical signals from the detector areprocessed into a ratio to provide a value that is proportional to theconstituent concentration—this being in percent or other engineeringunits, water content and oil based mud content can thereby be monitored.This technology is well defined and provides high accuracy and speed ofresponse to facilitate on-line measurement and control of the dryerprocess.

Alternative methods according to the present invention of obtaining a“wetness” value include passing the product through an open mesh andmeasuring the pressure drop generated. A rise in pressure drop indicatesproduct adhering to the mesh most likely due to a rise in the “wetness”value. Dielectric constant based instrumentation or vibratory sensitiveinstrumentation may also be used to monitor change in consistency.

Use of information can minimize the “mixing” of cuttings with storagevessels. In one aspect a dedicated storage tank is used if a desired“wetness” value is exceeded. In one such system a bank of storagevessels are filled with drilled cuttings of a satisfactory consistencyand oily if the desired wetness value is exceeded, then the flow isdiverted to a “wet” storage tank and an alarm raised such that theoperator can then resolve the situation. In another system according tothe present invention a screw conveyor being used to feed the conveyingsystem after the dryer may be immediately reversed in order to feed adedicated “wet” tank. In another system according to the presentinvention two dryers are used each fitted with a screen with a differentmesh size. Should one dryer blind or malfunction resulting in a “wet”cuttings discharge, then the cuttings can be redirected by actuating anappropriate valve below the dryer feed conveyor in order to use thealternative dryer. In another system according to the present inventionoverall height required is reduced through the use of screw conveyors.

The present invention, in certain aspects, provides a method for movingdrilled cuttings from an offshore rig located in water to a boat in thewater adjacent said offshore rig, said drilled cuttings laden withdrilling fluid, the method including feeding drilled cuttings from adrilling operation to a cuttings processor, the cuttings processorcomprising a rotating annular screen apparatus, processing the drilledcuttings with the cuttings processor producing processed drilledcuttings and secondary material, the secondary material includingdrilled cuttings and drilling fluid, the processed drilled cuttingsincluding drilling fluid, feeding the processed drilled cuttings fromthe cuttings processor to positive pressure blow tank apparatus, thepositive pressure blow tank apparatus having a tank which receives theprocessed drilled cuttings from the cuttings processor, feeding thesecondary material from the cuttings processor to secondary apparatus,and supplying air under pressure to the tank of the positive pressureblow tank apparatus for expelling drilled cuttings from the tank andpropelling the drilled cuttings to tertiary apparatus. In one particularaspect the secondary apparatus is decanting centrifuge apparatus, themethod further including processing the secondary material with thedecanting centrifuge apparatus, producing secondary drilling fluid andsecondary drilled cuttings. In one aspect, prior to feeding drilledcuttings from the cuttings processor to the positive pressure blow tankapparatus, the drilled cuttings are fed to mill apparatus to break upagglomerations of the drilled cuttings and then feeding them from themill apparatus to the positive pressure blow tank apparatus.

In one aspect, in methods wherein the secondary apparatus is decantingcentrifuge apparatus, the methods include processing the secondarymaterial with the centrifuge apparatus, producing secondary drillingfluid and secondary drilled cuttings, recycling said secondary drillingfluid for reuse in a drilling operation, feeding said secondary drilledcuttings to a mill apparatus for breaking up agglomerations of saidsecondary drilled cuttings, feeding secondary drilled cuttings from themill apparatus to the positive pressure blow tank apparatus; and/orprior to feeding drilled cuttings from the cuttings processor to thepositive pressure blow tank apparatus, feeding said drill cuttings tomill apparatus to break up agglomerations of said drilled cuttings andthen feeding said drilled cuttings from the mill apparatus to thepositive pressure blow tank apparatus.

The present invention, in certain aspects, provides a method for movingdrilled cuttings material, the drilled cuttings material includingdrilled cuttings and drilling fluid, the method includes feeding thedrilled cuttings material to cuttings processor apparatus, the cuttingsprocessor apparatus including rotating annular screen apparatus,processing the drilled cuttings material with the cuttings processorproducing processed drilled cuttings and secondary material, thesecondary material including drilled cuttings and drilling fluid, saidprocessed drilled cuttings including drilling fluid, conveying withfluid under positive pressure processed drilled cuttings from thecuttings processor to flow conduit apparatus, applying air underpositive pressure to the flow conduit apparatus to continuously move theprocessed drilled cuttings therethrough, continuously moving theprocessed drilled cuttings with the air under pressure to separationapparatus, and with the separation apparatus continuously separatingprocessed drilled cuttings from the air.

The present invention, in certain aspects, provides a system for movingdrilled cuttings, the system having movement apparatus for movingdrilled cuttings, cuttings processor apparatus for processing thedrilled cuttings for feed to tank apparatus, the cuttings processorapparatus including rotating annular screen apparatus, tank apparatusfor receiving drilled cuttings from the cuttings processor apparatus,flow conduit apparatus for receiving drilled cuttings from the tankapparatus, pressurized fluid apparatus for applying air under positivepressure to the drilled cuttings and for continuously moving the drilledcuttings through the flow conduit apparatus and to separation apparatus,and separation apparatus for continuously receiving the drilled cuttingsthrough the flow conduit apparatus, the separation apparatus forseparating the drilled cuttings from air.

The present invention, in certain aspects, provides a method ofconveying a paste, the paste including drilled cuttings laden withfluid, the method including feeding the paste to a cuttings processor,the cuttings processor comprising a rotating annular screen apparatus,reducing the weight of said paste with the cuttings processor byremoving fluid from the paste, the cuttings processor producing producedmaterial that includes drilled cuttings and fluid, feeding the producedmaterial from the cuttings processor into a vessel, applying acompressed gas to the vessel to cause the produced material to flow outof the vessel, the vessel including a conical hopper portion which, atleast during discharge of the produced material, forms the lower sectionof the vessel and the cone angle is below a critical value required toachieve mass flow of the produced material.

The present invention, in certain aspects, provides systems and methodsfor moving material that has a low slurry density, (e.g. with a specificgravity between 2.3 and 4.0 and, in one aspect, about 2.7 or lower) anda high particle density, (e.g. 2 lbs/gallon-4 lbs/gallon or higher) witha positive pressure pneumatic fluid, e.g. air or steam. In other aspectsthe cuttings to be treated, e.g. from shale shakers, have a specificgravity of 1.8 (1800 kg/m³; 15 lbs/gallon) and certain high densitycuttings have a specific gravity of 2.5 (21 lbs/gallon). In oneparticular aspect the material is a slurry that includes drilledcuttings from a wellbore, well drilling fluids, drilling muds, water,oil, and/or emulsions with the cuttings present as varying weightpercents of the slurry. “Slurry density” refers to material from a wellin an air flow and “particle density” refers to the material prior toits inclusion in an air flow.

In certain aspects systems and methods according to the presentinvention provide the continuous or almost-continuous transport ofmaterial.

In certain particular embodiments the present invention provides systemswith storage facilities for solids to be moved and apparatus for mixingheavy solids to be transported with a pneumatic fluid, e.g., but notlimited to, air or steam, at a positive pressure, i.e. above atmosphericpressure. In one aspect the velocity of moving solids is reduced using,e.g., a separator apparatus, and then the solids are collected incollection apparatus (e.g. tanks, boxes, storage containers). In certainaspects self-unloading tanks are used that have a positive pressuresolids removal system. Such tanks may have systems for measuring theamount of solids in the tanks and providing an indication of thisamount.

In one aspect the present invention provides apparatus for reduces thedensity of a slurry of material. Such apparatus includesdecelerator/separator apparatus.

In particular embodiments in a method according to the present inventiondrilled cuttings are collected from a drilling rig (in one aspect, asthey are produced) and then moved using positive pressure air and thenflowed into a slurry expansion chamber apparatus which reduces thedensity of the incoming material. The slurry is then transported throughconduit(s), e.g. at about 150 mph, 200 mph, 250 mph, or higher toseparator apparatus that separates solids in the slurry from the air.The separated solids can be stored, shipped, or moved to other apparatusfor further processing. In one such method about thirty-five tons perhour of solids are processed. In one aspect a slurry is, by volume,about fifty percent cuttings (plus wet fluid) and about fifty percentpneumatic fluid. In other aspects the cuttings (plus wet fluid) rangebetween two percent to sixty percent of the slurry by volume.

It is, therefore, an object of at least certain preferred embodiments ofthe present invention to provide:

New, useful, unique, efficient, non-obvious systems and methods fortransporting wet solids using positive pressure pneumatic fluid;

Such systems and methods in which the wet solids include drilledcuttings from a wellbore;

Such systems and methods which provide selective definite dosing ofdrill cuttings to apparatus beyond dosing apparatus for furtherprocessing; and

Such systems and methods which provide for the continuous oralmost-continuous transport of low slurry density, high particle densitymaterial; and

New, useful, unique, efficient and nonobvious apparatuses and devicesuseful in such systems and methods.

The present invention recognizes and addresses the previously-mentionedproblems and long-felt needs and provides a solution to those problemsand a satisfactory meeting of those needs in its various possibleembodiments and equivalents thereof. To one of skill in this art who hasthe benefits of this invention's realizations, teachings, disclosures,and suggestions, other purposes and advantages will be appreciated fromthe following description of preferred embodiments, given for thepurpose of disclosure, when taken in conjunction with the accompanyingdrawings. The detail in these descriptions is not intended to thwartthis patent's object to claim this invention no matter how others maylater disguise it by variations in form or additions of furtherimprovements.

The Abstract that is part hereof is to enable the U.S. Patent andTrademark Office and the public generally, and scientists, engineers,researchers, and practitioners in the art who are not familiar withpatent terms or legal terms of phraseology to determine quickly from acursory inspection or review the nature and general area of thedisclosure of this invention. The Abstract is neither intended to definethe invention, which is done by the claims, nor is it intended to belimiting of the scope of the invention in any way.

It will be understood that the various embodiments of the presentinvention may include one, some, or all of the disclosed, described,and/or enumerated improvements and/or technical advantages and/orelements in claims to this invention.

DESCRIPTION OF THE DRAWINGS

A more particular description of certain embodiments of the inventionmay be had by references to the embodiments which are shown in thedrawings which form a part of this specification.

FIGS. 1, 2, 3, 3A, 3B, 4 and 5 are schematic views of systems or partsthereof according to the present invention.

FIG. 4A is a schematic view of part of a system according to the presentinvention.

FIG. 4B is a schematic view of part of a system according to the presentinvention.

FIG. 6A is a top view of an air/solids separator according to thepresent invention.

FIG. 6B is a cross-section view of the separator of FIG. 6A.

FIG. 6C is a side view of the separator of FIG. 6A.

FIG. 6D is a front view of the separator of FIG. 6A.

FIG. 7 is a side cross-section view of slurry expansion chamberapparatus according to the present invention.

FIG. 8 is a side cross-section view of slurry expansion chamberapparatus according to the present invention.

FIG. 9 is a side schematic view of a separator according to the presentinvention.

FIGS. 10 and 11 are schematic views of a system according to the presentinvention.

FIG. 12 is a cross-sectional view of a prior art cuttings processor.

FIG. 13A is a top view in cross-section of a storage vessel according tothe present invention for use in methods according to the presentinvention.

FIG. 13B is a side cross-section view of the storage vessel of FIG. 13A.

FIG. 13C is an alternative embodiment of the storage vessel of FIG. 13A.

FIG. 13D is a top view of a frame for a system according to the presentinvention.

FIG. 14 is a schematic view of a system according to the presentinvention.

FIG. 15A is a schematic cross-section view of a prior art tank for usein a system as in FIG. 14.

FIG. 15B is a side cross-section view of a tank for use in a system asin FIG. 14.

FIG. 15C is a side view of the tank of FIG. 15B.

FIG. 15D is a rear view of the tank of FIG. 15B.

FIG. 16 is a side schematic view of a tank for use in methods accordingto the present invention.

FIG. 17A is a top view of part of the system of FIG. 13A.

FIG. 17B is a top view of part of the system of FIG. 13A.

FIG. 17C is a top view of part of the system of FIG. 13A.

FIG. 17D is a top view of part of the system of FIG. 13A.

FIG. 18 is a schematic view of a storage vessel system according to thepresent invention.

FIG. 19A is a top cutaway view of a vessel system according to thepresent invention.

FIG. 19B is a top cutaway view of a vessel system according to thepresent invention.

FIG. 19C is a top cutaway view of a vessel system according to thepresent invention.

FIG. 19D is a side cross-section view of the vessel system of FIG. 19A.

FIG. 19E is a side cross-section view of the vessel system of FIG. 19A.

FIG. 20A is a side schematic view of a vessel system according to thepresent invention.

FIG. 20B is a partial top view of part of the system of FIG. 20A.

FIG. 21A is a side schematic view of a vessel system according to thepresent invention.

FIG. 21B is an end view of part of the system of FIG. 21A.

FIG. 21C is a partial side view of the system of FIG. 21A.

FIG. 22 is a schematic view of a system according to the presentinvention.

FIG. 23 is a schematic view of a system according to the presentinvention.

FIG. 24 is a schematic view of a system according to the presentinvention.

FIG. 25 is a schematic view of a system according to the presentinvention.

FIG. 26 is a schematic view of a system according to the presentinvention.

FIG. 27 is a schematic view of a system according to the presentinvention.

FIG. 28 is a schematic representation showing an oil rig provided with asystem incorporating a dosing apparatus and storage vessels according tothe present invention.

FIG. 29 is a side view partially in cross-section of a dosing apparatusof the system of FIG. 28.

FIG. 29A is a schematic view of a system according to the presentinvention.

FIG. 30 is an end view of part of the dosing apparatus of FIG. 29.

FIG. 31 is a cross-sectional view of part of the dosing apparatus ofFIG. 29.

FIG. 32 is a schematic cross-sectional view of a storage systemaccording to the present invention.

FIG. 33 is a cross-sectional view along line 33-33 of FIG. 32.

FIG. 34 is a cross-section view of part of dosing apparatus according tothe present invention.

FIG. 34A is an alternative cross-section view of part of the system ofFIG. 34.

FIG. 34B is an alternative cross-section view of part of the system ofFIG. 34.

FIG. 34C is an alternative cross-section view of part of the system ofFIG. 34.

FIG. 34D is an alternative cross-section view of part of the system ofFIG. 34.

FIG. 35 is a cross-section view of part of dosing apparatus according tothe present invention.

FIG. 36 is a schematic view of a conveyance system according to thepresent invention.

FIG. 37A is a schematic view of a conveyance system according to thepresent invention.

FIG. 37B is a schematic view of a conveyance system according to thepresent invention.

FIG. 37C is a schematic view of a conveyance system according to thepresent invention.

DESCRIPTION OF EMBODIMENTS PREFERRED AT THE TIME OF FILING FOR THISPATENT

FIG. 1 shows a system 10 according to the present invention which hasone or more (three shown) shale shakers SS mounted on an offshore rigRG. The shale shakers process drilling fluid having drilling solids,drilled cuttings, debris, etc. entrained therein. Separated solidsand/or cuttings (with minimal liquid) exit the shale shakers S and arefed to a conveyor SC (or to any other suitable cuttings movementapparatus or device) which moves the separated solids to a feed openingTO of a tank TA.

Solids from the tank TA are pumped, optionally, by one or more pumps PP(two shown) in a line 16 and, optionally, to and through collectiondevices; e.g. optional cuttings boxes CB are shown in FIG. 1.Pressurized air from a pressurized air source flows to slurry expansionchambers SE in which the density of the solids pumped from the tank TAis reduced. In one particular embodiment air is provided at about 3000cubic feet per minute to 6000 cubic feet per minute (or about 400 to 800ACFM (actual cubic feet per minute at 100 p.s.i.) air pressure in a line16 ranges between 15 and 40 p.s.i.; and, preferably, the solids densityis relatively low, e.g. between 1 and 2 pounds per gallon of fluidflowing in the line 16. The solids are impelled from the slurryexpansion chambers SE by the pressurized air into lines 12 and 14 thatflow into the line 16. Desirably, one such system will process 20 to 40tons of material per hour. Preferably solids, cuttings, etc. flowcontinuously in the line 16 to storage tanks on a boat BT.

Floats FT may be used with the line 16 and tether/disconnect apparatusTD provides selective and releasable connection of the line 16 tocorresponding flow lines 18 and 19 of the storage tank systems ST.Optionally, air/solids separators AS may be used to remove air from theincoming fluid and/or to concentrate the solids therein. Air escapesfrom the systems ST via gas outlets GO and solids exiting the systems STflow directly to a dock/shipping facility or are collected in containerson the boat BT. The line 16 and/or tether/disconnect apparatus TD may besupported by a crane CR on the rig RG. It is also within the scope ofthis invention for its systems and methods to be used on land.

In one particular aspect the systems ST employ self-unloading storagetanks which have one or more air inlets on their sides with pressurizedair flow lines connected thereto to prevent wet solids build upon thetanks internal walls and interior surfaces and to facilitate solidsmovement from the tanks. Optional air assist devices AD through whichair under pressure is introduced into the line 16 may be used on theline 16 to facilitate solids flow therethrough.

FIG. 2 shows a system 20 according to the present invention, like thesystem 10 (like numerals and letters indicate like parts), but withtanks TK receiving solids from the tank TA. The solids flow by gravityinto the tanks TK. Alternatively, or in addition to gravity flow, thesolids may be moved by suitable conveyor apparatus, screw conveyor(s),belt movement apparatus, etc. Valves VL selectively control flow intothe tanks TK and valves VV selectively control flow from the tanks TKinto flow lines 21, 22. Pressurized air from a pressurized air source PSforces the solids from lines 21, 22 into a line 23 (like the line 16,FIG. 1).

FIG. 3 shows a system 30 according to the present invention, in whichsome parts and apparatuses are like those of the systems 10 and 20 (likenumerals and letters indicate like apparatuses and items). Materialflows in the line 23 to a separator SR from which solids flow to a tankTC of a system TN. Gas (primarily if not wholly air) flows out from anopening OP of the separator SR. Pumps PM (one, two, or more) (e.g.cement pumps or progressive cavity pumps) pump solids from the tank TCin lines 31, 32 and 33 to a vortex dryer VD. In certain aspects only oneof the pumps PM is operational at any given time. One, two or more tanksTC may be used. Separated solids exit from the bottom of the vortexdryer VD. In one particular aspect the cuttings coming out of the bottomof the vortex dryer are about 95% dry, i.e., 5% by weight of the solidsexit stream is oil, drilling fluid, etc. In certain aspects the systems20 and 30 achieve continuous flow of 20 to 40 tons of solids per hour.An ultrasonic meter UM indicates the depth of solids in the tank TC andtank sensors TS measure the weight of solids therein. FIG. 3A shows asystem 30 a, like the system 30, FIG. 3 (like numerals indicate likeparts); but the vortex dryer VD is replaced by a cuttings processor 30 b(like the cuttings processor 110, FIG. 10, described below).

FIG. 4 shows a system 40 according to the present invention which hassome apparatuses and items like the systems 10, 20 and 30 (and likenumerals and letters indicate like apparatuses and items). The separatorSR separates solids from air in the line and feeds them primarily viagravity (optionally with a pressurized air assist) to one or morecuttings boxes CT. Air may be vented from opening(s) in the box CT.According to the present invention a separator SR can be a separateapparatus interconnected with a tank or box in fluid communicationtherewith or it can be built into a tank or box as are integral partthereof. In one particular aspect the cuttings box CT is a commerciallyavailable Brandt FD-25 (Trademark) Cuttings Box. FIG. 4A illustratesthat the separator SR can be replaced with a cuttings processor CP (likethe cuttings processor 110, FIG. 10, described below) that feedsprocessed cuttings to the box CT and that any separator SR in any systemherein can be so replaced.

FIG. 4B illustrates that any tank TA in any system herein can be fedwith cuttings from a cuttings processor CQ (like the cuttings processor110, FIG. 10, described above).

FIG. 5 shows a system 50, like the system 20 (like numerals and lettersindicate like apparatuses and items), but with material fed in the line23 to a separator SR on a cuttings box CT.

FIGS. 6A-6D show one embodiment of a separator 60 according to thepresent invention which may be used as the separator SR, above. A top 64a, mid section 64 b, and lower section 64 c are bolted together to forma housing 64. Material is fed into the top section 64 a through a feedinlet 61 that is, preferably, tangent to the diameter. Gas flows outthrough a top opening 62. Mounted within the housing 64 is a generallycylindrical hollow vortex finder 65. In one particular aspect thediameter of the vortex finder 65 and the diameter of a solids exitopening 66 of the lower section 64 c are sized so that the flow from theopening 66 is primarily solids (e.g. between about 80% to 99% solids byweight) and the flow of gas out of the top opening 62 is primarily (99%or more) air; e.g. with a housing 64 that is about 48 inches in height,with a mid section 64 b about 24 inches in diameter, the top opening 62is about 12 inches in diameter and the bottom opening 66 is about 10inches in diameter. It is within the scope of this invention to providesuch an apparatus with dimensions of any desired size.

Mounts 67 facilitate mounting of the separator SR on a tank, rig, boat,or other structure. Any suitable support, e.g. one or more posts 68, maybe used.

FIG. 7 shows a slurry expansion chamber apparatus 70 according to thepresent invention which has a main hollow body 71 with an opening 72.Material M flows through a feed tube 73 (e.g. cuttings, fluid, andmaterial from a wellbore) through the opening 72 into the main hollowbody 71. Air under pressure from any suitable pressurized air source isintroduced into a feed conduit 74 and then into a nozzle 75. The airmixes with the material M, reduces its density, and propels thereduced-density material R out through an exit opening 76. Optionallythe nozzle 75 is deleted and the air flow and/or movement into theexpansion chamber reduces the density of the material.

FIG. 8 shows a slurry expansion chamber apparatus 80 according to thepresent invention which has a main hollow body 81 with an opening 82.Material L flows through a feed tube 83 (e.g. cuttings, fluid andmaterial from a wellbore) through the opening 82 into the body 81. Airunder pressure from a pressurized air source is introduced into a feedconduit 84 and then into a nozzle 85. The air mixes with the material L,reduces its density, and propels the reduced-density material T outthrough an exit opening 86. The apparatus in FIGS. 7 and 8 may be usedas the slurry expansion chamber apparatuses in the systems of FIGS. 1-5.

FIG. 9 shows an air/solids separator 90 usable as the separators AS,FIG. 1, mounted on a base 99. A mixture of air and solids is introducedinto a tank 91 through a feed conduit 92. Solids flow by gravity to anexit opening 93.

Optionally, a slurry expansion chamber apparatus SE receives the solidsand propels them through a pipe 98 to storage, to a collection tank ortanks, or to a cuttings box, on shore, on a rig, or on a boat or barge.Air flows out from a top opening 94.

Optionally the separator 90 may be provided with a motor apparatus 95(e.g., a gear-box/air-motor-apparatus device) that rotates a screw 97that inhibits or prevents the bridging of solids within the tank 91.Alternatively or in addition to such motor apparatus, devices like theair assist devices AD described above may be used to inhibit suchbridging.

A valve 96 (e.g., an air-operated valve) selectively closes off theopening 93 as desired.

The present invention, therefore, in at least certain embodiments,provides a method for moving drilled cuttings material, the methodincluding conveying with fluid under positive pressure drilled cuttingsmaterial to flow conduit apparatus, applying fluid (e.g., air or steam)under positive pressure to the flow conduit apparatus to continuouslymove the drilled cuttings material therethrough, continuously moving thedrilled cuttings material with the fluid under pressure to separationapparatus, and with the separation apparatus continuously separatingdrilled cuttings from the fluid.

Such a method may also include one or some (in any possible combination)of the following: wherein the drilled cuttings are included in a lowdensity slurry with drilling fluid; wherein the separation apparatus isa cyclone separator and the drilled cuttings moved into the cycloneseparator are wet; wherein a flow pipe interconnects the separationapparatus in fluid communication with drying apparatus, the methodfurther including flowing wet drilled cuttings through the flow pipe tothe drying apparatus, and drying the wet drilled cuttings with thedrying apparatus; flowing the drilled cuttings material to expansionchamber apparatus, and reducing density of the drilled cuttings materialin the expansion chamber apparatus; wherein the density of the drilledcuttings material is reduced by flowing air into the material within theexpansion chamber apparatus; wherein the air flows into and out througha nozzle within the expansion chamber apparatus; wherein the drilledcuttings flow in a main conduit to the separation apparatus, the mainconduit having at least one air movement assistance device, the methodfurther including facilitating movement of the drilled cuttings materialthrough the main conduit with air from the at least one air movementassistance device; moving separated drilled cuttings from the separationapparatus to collection apparatus, the collection apparatus from thegroup consisting of cuttings box or boxes, tank or tanks, storagedevice, container or containers, and receptacle(s) on a boat or barge;wherein prior to conveying drilled cuttings material to the flow conduitapparatus the material is fed into tank apparatus, the method furtherincluding pumping the material from the tank apparatus into the flowconduit apparatus; wherein the pumping includes pumping the materialfrom the tank apparatus into expansion chamber apparatus andtherethrough into the flow conduit apparatus; wherein the tank apparatusincludes valve apparatus for selectively controlling flow of thematerial into the flow conduit apparatus; wherein at least a portion ofthe flow conduit apparatus is in water and float apparatus is on theflow conduit apparatus, the method further including facilitatingfloating of at least a portion of the flow conduit apparatus in thewater with the float apparatus; wherein the drying apparatus is a vortexdryer; wherein the drilled cuttings material is included within a slurryof material, wherein the slurry has a low slurry density, and whereinupon mixing of the slurry with the fluid under positive pressure aresultant slurry is produced, the resultant slurry having a highparticle density; and/or wherein the slurry has a specific gravitybetween 2.3 and 4.0 and the particle density of the resultant slurry isbetween 2 pounds/gallon and 4 pounds/gallon.

The present invention, therefore, in at least certain embodiments,provides a method for moving drilled cuttings material, the methodincluding conveying with fluid (e.g., air) under positive pressuredrilled cuttings material to flow conduit apparatus, applying air underpositive pressure to the flow conduit apparatus to continuously move thedrilled cuttings material therethrough, continuously moving the drilledcuttings material with the air under pressure to separation apparatus,with the separation apparatus continuously separating drilled cuttingsfrom the air, wherein the separation apparatus is a cyclone separatorand the drilled cuttings moved into the cyclone separator are wet,wherein a flow pipe interconnects the separation apparatus in fluidcommunication with drying apparatus, flowing wet drilled cuttingsthrough the flow pipe to the drying apparatus, drying said wet drilledcuttings with the drying apparatus, flowing the drilled cuttingsmaterial to expansion chamber apparatus, and reducing density of thedrilled cuttings material in the expansion chamber apparatus, whereinthe density of the drilled cuttings material is reduced by flowing airinto said material within the expansion chamber apparatus, movingseparated drilled cuttings from the separation apparatus to collectionapparatus from the group consisting of cuttings box, tank, storagedevice, container, and receptacle on a boat, wherein the drilledcuttings material is included within a slurry of material, wherein theslurry has a low slurry density, and wherein upon mixing of the slurrywith the fluid under positive pressure a resultant slurry is produced,the resultant slurry having a high particle density, and wherein theslurry has a specific gravity between 2.3 and 4.0 and the particledensity of the resultant slurry is between 2 pounds/gallon and 4pounds/gallon.

The present invention, therefore, in at least certain embodiments,provides a system for moving drilled cuttings, the system havingmovement apparatus for moving drilled cuttings, tank apparatus intowhich the movement apparatus can move the drilled cuttings, flow conduitapparatus for receiving the drilled cuttings from the tank apparatus,pressurized fluid apparatus for applying air under positive pressure tothe drilled cuttings and for continuously moving the drilled cuttingsthrough the flow conduit apparatus and to separation apparatus, andseparation apparatus for continuously receiving the drilled cuttingsthrough the flow conduit apparatus, the separation apparatus forseparating the drilled cuttings from air; and such a system wherein thedrilled cuttings are wet and the system further has drying apparatus fordrying the drilled cuttings.

FIG. 10 shows a system 100 according to the present invention which hasshale shakers SS (e.g. as in FIG. 1) whose processed solids, drilledcuttings, etc. are fed by a conveyor SC (as in FIG. 1) to a cuttingsprocessor 110 which is a rotating annular screen apparatus, which,optionally is formed in a conical shape, e.g., as disclosed in U.K.Patent Application GB 2,297,702 A published Aug. 14, 1996 (incorporatedfully herein for all purposes). (Commercially available embodiments ofsuch annular screen apparatus are available from Don Valley EngineeringCompany Limited, including, but not limited to, its models MUD 8 and MUD10.) A method using one such annular screen apparatus includes applyinga mixture with drill cuttings and drilling fluid to the inner surface ofan annular filter screen, rotating the annular filter screen, theannular screen having a plurality of apertures, the apertures being of asize such that the drilling fluid can pass through the apertures butdrill cuttings with oil are substantially prevented from passing throughthe apertures. The cuttings processor 110 significantly reduces theamount of fluid in the drilled cuttings; e.g., in one particularembodiment from about 15% to 20% fluid by weight in the drilled cuttingsto about 1% to 3% therein. In one particular aspect the cuttingsprocessor 110 and others herein like it fit within a 1 meter cube; hencethey take up minimal space on a rig or on a boat.

The treated drilled cuttings are then introduced into a hopper 112 fromwhich they flow into a blow tank 120. A valve 113 selectively controlsflow from the hopper 112 to the blow tank 120. Air under pressure, e.g.at least 75 psi (in one aspect between 75 and 150 psi and in one aspectabout 125 psi), flows into the blow tank 120 in a line 114 from apositive pressure air source 115. In one aspect, all of the items SS,SC, 110, 112, 120, 114 and 115 and their associated lines, valves andcontrols are all located on a drilling rig, in one aspect an offshoredrilling rig. The blow tank 120 may be like the tanks TK and theirassociated apparatus, FIG. 2 or FIG. 3.

In the offshore drilling rig situation, as shown in FIG. 10, processeddrill cuttings are fed from the blow tank 120 (with the valve 135 open),with a valve 123 closed, and a valve 122 and 136 open, and with a valve142 closed, in a line 121 to a cuttings box CB (like those describedabove) on a ship 116 in the water adjacent the offshore rig. Optionallywith valve 36 closed and valve 124 open, the drilled cuttings are fed toa blow tank 127 from which they can be fed to any suitable on-ship oroff-ship storage device or processing apparatus. A pressurized airsource 141 on the ship provides air under pressure to the blow tank 127.

Optionally either or both of the cuttings box CB or the blow tank 127can be fed with drilled cuttings processed by a cuttings processor 130or 140, respectively, as indicated by the dotted lines in FIG. 10. Inone aspect with the valve 122 closed and a valve 142 open, drilledcuttings are fed from the blow tank 120 in a line 125 to a cuttingsprocessor 130 (like the cuttings processor 110) and processed cuttingsare fed in a line 126 to the cuttings box CB. In one aspect with theappropriate valves open and the appropriate valves closed, including avalve 124 closed, drilled cuttings are fed in a line 128 from the blowtank 120 to a cuttings processor 140 (like the cuttings processor 110)and processed cuttings are fed in a line 129 to the blow tank 127. Avalve 132 selectively controls the flow of drilled cuttings from theblow tank 127. In one aspect drilled cuttings from the blow tank 127 arefed in a line 131 to a cuttings processor 150 (like the cuttingsprocessor 110) and processed cuttings flow in a line 133 from thecuttings processor 150 (e.g. to a cuttings box, to other storageapparatus, or to off-ship storage or processing.

In one particular embodiment of a system as described in FIG. 10 above,drilled cuttings conveyed to the cuttings processor 110 have 15% to 20%fluid by weight and drilled cuttings fed from the cuttings processor 110to the hopper 112 have 1% to 3% fluid by weight. As desired any numberof positive pressure air assist devices 146 can be used on the line 121.In one particular embodiment for about 1 cubic meter of total materialfed to the cuttings processor 110, about 0.5 cubic meter is received bythe blow tank 120.

It is to be understood that the cuttings processors used in certainembodiments of the present invention (like the processor 110 and thoselike it) receive material that includes drilled cuttings and recoverabledrilling fluid. The cuttings processor produces primary drilled cuttingswhose drilling fluid component is much less by weight than thefluid-laden material in the initial feed. As shown in FIG. 3B primarydrilled cuttings from the processor 110 are, in one particularembodiment, fed to mill apparatus 170 to break up agglomerated masses ofdrilled cuttings. The mill apparatus, in one aspect, is a pug mill. Themill apparatus 170 produces drilled cuttings with some fluid thereinwhich are fed in a line 171 to the blow tank 120. The processor 110 alsoproduces a secondary stream 172 that contains drilling fluid and somedrilled cuttings. The stream 172, in one aspect, is fed to furtherprocessing apparatus which, in one aspect, is one or more decantingcentrifuges, e.g. decanting centrifuge apparatus 173, which producesrecyclable drilling fluid that exits in a line 174 and drilled cuttings175 with some drilling fluid therein. The drilling fluid 174 is fed backinto a rig mud system for re-use in a drilling operation. The drilledcuttings 175, which may be in the form of a paste, are, in one aspect,fed to the mill apparatus 170; or are fed to the blow tank 120 withoutmilling (shown by dotted line, FIG. 3B). Any system herein may employmill apparatus 170 and/or further processing apparatus like theapparatus 173.

As shown in FIG. 3B, to measure the amount of material within the blowtank 120 and the amount fed to and within the cuttings box CB, load cellapparatus 176 is used on the blow tank 120 and the cuttings box CB whichcan provide continuous monitoring of the weight of material in theseapparatuses; and, optionally, ultrasonic level probes 177 monitor thelevel of material in these apparatuses. Optionally, timer apparatus 178monitors the time of flow into the blow tank 120.

FIG. 11 shows a system 200 according to the present invention which isan improvement of systems disclosed in European Patent EP 1,187,783 B1granted Sep. 24, 2003 (incorporated fully herein for all purposes). Anoffshore oil rig 201 has located on a platform 203 a pressure vessel 205into which is loaded screened drill cuttings arising from a drillingprocess. The pressure vessel 205 includes an upper material inlet and alower material outlet as well as apparatus for supplying compressed airto the interior of the vessel. The material inlet includes a valveassembly and the entire vessel may be similar to that manufactured andsold by Clyde Materials Handling Limited. Initially, drilled cuttingsare fed to a cuttings processor 210 (like the processor 110, FIG. 10)and the cuttings processed by the cuttings processor 210 are fed to thepressure vessel 205. The material from the processor 210 may be afree-flowing or a non-free flowing paste depending on how much fluid thecuttings processor 210 removes.

The pneumatic conveying system, including the pressure vessel 205,follows a cycle of filling and discharging material from the pressurevessel. At the start of the cycle, the material inlet valve is closed. Avent valve is opened to equalize vessel pressure to ambient air. Theinlet valve is opened and the oil cuttings/oil mixture is fed into thepressurized vessel. The vent valve is opened to vent displaced air fromthe vessel. When the pressurized vessel if full, the inlet valve closes.The vent valve also closes and the vessel is now sealed. An air inletvalve is opened and the material is conveyed along a pipe 207 whichextends from a position below pressurized vessel 205 to an elevatedposition above a container assembly 209. Assembly 209 can include threeISO container sized vessels 211 located within a support framework 214.(In other embodiments, the container assembly may include a number ofvessels 211 other than three.) Pipe 207 extends above the top ofcontainer assembly 209 and has downwardly extending branches leadinginto the inlets of each of the containers 211.

Each container 211 has a lower conical shaped hopper portion 215 and atthe lowermost point of this portion there is a valve inlet 217 wherebythe material within the containers 211 may be discharged via pipe 219 toa hose connection pipe 221.

A supply boat 223, fitted with a further container assembly 225, may bebrought close to the oil rig 201. A flexible hose 227 is connected topipe 219 at hose connection pipe 221. At its other end hose 227 isconnected to a filling pipe 229 located on boat 223. Filling pipe 229leads from the rear of boat 223 to a position above container assembly225 and branch pipes extends downwardly from pipe 229 to the inlets ofeach of the containers 231 forming part of the containers assembly 225.

Optionally, using appropriate valving and controls (not shown) materialin the flexible hose 227 is fed to a cuttings processor 250 (like thecuttings processor 110, FIG. 10) on the boat 223 which then providesprocessed cuttings to the container assembly 225. Optionally, cuttingsfrom the container assembly 225 are fed to a cuttings processor 252(like the cuttings processor 110, FIG. 10) from which processed cuttingsmay be provided to storage or further processing on the boat 223 and/oron shore.

FIG. 12 illustrates a prior art rotating annular screen apparatus asdisclosed in U.K. Patent Application GB 2,297,702 A published Aug. 14,1996, which e.g., in certain aspects, can serve as the cuttingsprocessor 110, FIG. 10, and the like cuttings processors mentionedabove.

The cuttings processor 301 in FIG. 12 is a vibrating centrifuge for usewith the present invention, consisting of an outer body 303, a conicalscreen 305 having a small radius end 306 and a large radius end 308, adrive shaft 307 for rotating the conical screen 305 and a feed tube 209.The conical screen 305 is rotated by the drive shaft 307 with acentrifugal force acting on the conical screen 305, e.g. a force ofbetween 10 g and 200 g. A linear motion is applied along thelongitudinal axis of the drive shaft 307, e.g. with a force per unitmass of up to 5 g and an amplitude of up to 10 mm. As the conical screen305 is directly coupled to the drive shaft 307, this linear motion isimparted onto the conical screen 305. The angle of the conical screen305 is critical to the efficiency of the process and can range from 10degrees to 110 degrees depending on the efficiency required. A mixtureof drilling cuttings and oil, e.g., oil in oil based drilling mud, isconveyed into the input port 311, falls down the feed tube 209 and isguided onto the small radius and 306 of the conical screen 305 by a feedtube guide 313. The vibrating centrifuge separates the drilling mud fromthe drilling cuttings by the combination of the centrifugal forcesupplied by the rotating conical screen 305, the linear motion impartedon the conical screen 305 and the angle of the conical screen 305.

As the mixture of drilling mud and drilling cuttings are conveyed ontothe rotating conical screen 305, the centrifugal force forces thedrilling mud to migrate through apertures in the conical screen 305.However, the apertures are of a size such that the drilling cuttings aretoo large to migrate through the apertures in the conical screen 305,and hence are retained on an inside surface 315 of the conical screen301. The linear motion, which is produced by the drive assembly of thevibrating centrifuge, conveys the retained drilling cuttings towards thelarge radius end 308 of the conical screen 305. Because of the conicalform of the screen 305, as the drilling cuttings are conveyed towardsthe large radius end 308 of the conical screen 305, the force per unitmass acting on the drilling cuttings increases and so further removingany remaining residual oil based drilling mud from the drillingcuttings. The recovered drilling mud flows off the outside surface 317of the conical screen 305 and exits the outer body 303 through recoveredmud exit pipe 319. After the drilling cuttings have been conveyed alongthe length of the conical screen 305 and passed through the large radiusend 308, the drilling cuttings exit the outer body 303 through drydrilling cutting exit ports 321, 323. In one particular aspect, thelevel of oil retained on the drilling cuttings after the cuttings havebeen ejected from the vibration centrifuge is reduced to between 0.015kg and 0.04 kg of oil per kilogram of drilling cuttings.

The present invention, therefore, in at least certain embodiments,provides a method for moving drilled cuttings from an offshore riglocated in water to a boat in the water adjacent said offshore rig, saiddrilled cuttings laden with drilling fluid, said method includingfeeding drilled cuttings from a drilling operation to a cuttingsprocessor, said cuttings processor comprising a rotating annular screenapparatus; processing the drilled cuttings with the cuttings processorproducing processed drilled cuttings and secondary material, thesecondary material including drilled cuttings and drilling fluid, saidprocessed drilled cuttings including drilling fluid; feeding theprocessed drilled cuttings from the cuttings processor to positivepressure blow tank apparatus, said positive pressure blow tank apparatushaving a tank which receives said processed drilled cuttings from saidcuttings processor; feeding the secondary material from the cuttingsprocessor to secondary apparatus, and supplying air under pressure tothe tank of the positive pressure blow tank apparatus for expellingdrilled cuttings from said tank and propelling said drilled cuttings totertiary apparatus. Such a method may include one or some, in anypossible combination, of the following: wherein the tertiary apparatusis storage apparatus; wherein the tertiary apparatus includes asecondary positive pressure blow tank apparatus for facilitatingmovement of drilled cuttings from the storage apparatus; wherein drilledcuttings from the positive pressure blow tank apparatus are fed in aline to the tertiary apparatus, the line having at least one positivepressure air assist device for facilitating movement of drilled cuttingsthrough the line, the method further include facilitating drilledcuttings movement through the line with the at least one positivepressure air assist device; wherein the cuttings processor reduces theweight of drilled cuttings processed by removing drilling fluid fromsaid drilled cuttings, said removed drilling fluid not fed to saidpositive pressure blow tank apparatus; reducing a load on the positivepressure blow tank apparatus and on the tertiary apparatus by removingdrilling fluid from said drilled cuttings with said cuttings processor;wherein the secondary apparatus is decanting centrifuge apparatus, themethod further including processing the secondary material with thedecanting centrifuge apparatus, producing secondary drilling fluid andsecondary drilled cuttings; recycling said secondary drilling fluid forreuse in a drilling operation; feeding said secondary drilled cuttingsto mill apparatus for breaking up agglomerations of said secondarydrilled cuttings, and feeding secondary drilled cuttings from the millapparatus to the positive pressure blow tank apparatus; and/or prior tofeeding drilled cuttings from the cuttings processor to the positivepressure blow tank apparatus, feeding said drilled cuttings to millapparatus to break up agglomerations of said drilled cuttings and thenfeeding said drilled cuttings from the mill apparatus to the positivepressure blow tank apparatus.

The present invention, therefore, in at least certain embodiments,provides a method for moving drilled cuttings from an offshore riglocated in water to another location, in one aspect to a boat in thewater adjacent said offshore rig, said drilled cuttings laden withdrilling fluid, said method including feeding drilled cuttings from adrilling operation to a cuttings processor, the drilled cuttings ladenwith drilling fluid, said cuttings processor comprising a rotatingannular screen apparatus, processing the drilled cuttings with thecuttings processor producing processed drilled cuttings and secondarymaterial, the secondary material including drilling fluid and drilledcuttings, said processed drilled cuttings including drilling fluid,feeding processed drilled cuttings from the cuttings processor topositive pressure blow tank apparatus, said positive pressure blow tankapparatus having a tank which receives said processed drilled cuttingsfrom said cuttings processor, supplying air under pressure to the tankof the positive pressure blow tank apparatus for expelling processeddrilled cuttings from said tank and propelling said processed drilledcuttings to tertiary apparatus, wherein drilled cuttings from thepositive pressure blow tank apparatus are fed in a line to the tertiaryapparatus, the line having at least one positive pressure air assistdevice for facilitating movement of drilled cuttings through the line,the method further including facilitating drilled cuttings movementthrough the line with the at least one positive pressure air assistdevice, wherein the cuttings processor reduces the weight of drilledcuttings processed thereby by removing drilling fluid from said drilledcuttings, said drilling fluid not fed to said positive pressure blowtank apparatus, and thereby reducing a load on the positive pressureblow tank apparatus and on the further apparatus. Such a method mayinclude the following: wherein the secondary apparatus is decantingcentrifuge apparatus, the method further including processing thesecondary material with the decanting centrifuge apparatus, producingsecondary drilling fluid and secondary drilled cuttings, recycling saidsecondary drilling fluid for reuse in a drilling operation, feeding saidsecondary drilled cuttings to a mill apparatus for breaking upagglomerations of said secondary drilled cuttings, feeding secondarydrilled cuttings from the mill apparatus to the positive pressure blowtank apparatus, and prior to feeding drilled cuttings from the cuttingsprocessor to the positive pressure blow tank apparatus, feeding saiddrill cuttings to mill apparatus to break up agglomerations of saiddrilled cuttings and then feeding said drilled cuttings from the millapparatus to the positive pressure blow tank apparatus.

The present invention, therefore, in at least certain embodiments,provides a method for moving drilled cuttings material, the drilledcuttings material including drilled cuttings and drilling fluid, themethod including feeding the drilled cuttings material to cuttingsprocessor apparatus, the cuttings processor apparatus having rotatingannular screen apparatus, processing the drilled cuttings material withthe cuttings processor producing processed drilled cuttings andsecondary material, the secondary material including drilled cuttingsand drilling fluid, said processed drilled cuttings including drillingfluid, conveying with fluid under positive pressure processed drilledcuttings from the cuttings processor to flow conduit apparatus, applyingair under positive pressure to the flow conduit apparatus tocontinuously move the processed drilled cuttings therethrough,continuously moving the processed drilled cuttings with the air underpressure to separation apparatus, and with the separation apparatuscontinuously separating processed drilled cuttings from the air. Such amethod may include one or some, in any possible combination, of thefollowing: flowing the processed drilled cuttings to expansion chamberapparatus, and reducing density of the processed drilled cuttings in theexpansion chamber apparatus; wherein the density of the drilled cuttingsmaterial is reduced by flowing air into said material within theexpansion chamber apparatus; moving separated drilled cuttings from theseparation apparatus to further apparatus from the group consisting ofcuttings box, tank, storage device, container, receptacle on a boat,decanting centrifuge apparatus, and secondary rotating annular screenapparatus; wherein the drilled cuttings material is included within aslurry of material, wherein the slurry has a low slurry density, andwherein upon mixing of the slurry with the fluid under positive pressurea resultant slurry is produced, the resultant slurry having a highparticle density; and/or wherein the slurry has a specific gravitybetween 2.3 and 4.0 and the particle density of the resultant slurry isbetween 2 pounds/gallon and 4 pounds/gallon.

The present invention, therefore, in at least certain embodiments,provides a system for moving drilled cuttings, the system includingmovement apparatus for moving drilled cuttings, cuttings processorapparatus for receiving drilled cuttings from the movement apparatus andfor processing the drilled cuttings for feed to tank apparatus, thecuttings processor apparatus including rotating annular screenapparatus, tank apparatus for receiving drilled cuttings from thecuttings processor apparatus, flow conduit apparatus for receivingdrilled cuttings from the tank apparatus, pressurized fluid apparatusfor applying air under positive pressure to the drilled cuttings and forcontinuously moving the drilled cuttings through the flow conduitapparatus and to separation apparatus, and separation apparatus forcontinuously receiving the drilled cuttings through the flow conduitapparatus, the separation apparatus for separating the drilled cuttingsfrom air.

The present invention, therefore, in at least certain embodiments,provides a method of conveying a paste, the paste including drilledcuttings laden with fluid, the method including feeding the paste to acuttings processor, the cuttings processor comprising a rotating annularscreen apparatus, reducing the weight of said paste with the cuttingsprocessor by removing fluid from the paste, the cuttings processorproducing produced material that includes drilled cuttings and fluid,feeding the produced material from the cuttings processor into a vessel,applying a compressed gas to the vessel to cause the produced materialto flow out of the vessel, the vessel including a conical hopper portionwhich, at least during discharge of the produced material, forms thelower section of the vessel and the cone angle is below a critical valuerequired to achieve mass flow of the produced material. In such a methodthe paste may be a free-flowing paste or a non-free-flowing paste; sucha method may be accomplished on a rig or on a boat or partially on a rigand partially on a boat; and/or such a method may include feedingprocessed drilling cuttings processed by said method to a boat in wateradjacent said offshore rig, said drilling cuttings having less drillingfluid therein by weight than the drilling cuttings initially fed to thecuttings processor; and in such a method fluid content of said processeddrilling cuttings is at least 500% less by weight than fluid content ofthe drilled cuttings fed to the cuttings processor.

Referring to FIGS. 13A and 13B, a storage vessel 301 according to thepresent invention has a generally cylindrical pressure vessel 302 ofcircular cross-section with a substantially circular planar base 3 and adomed cap 4. The planar base 303 and the domed cap 304 may be formedintegrally or be welded to the wall of the pressure vessel 302.

The pressure vessel 302 may be made of steel of the type defined byBritish Standard 1501 224-49B and may be designed to withstand a workingpressure of between 1 and 20 Bar, and in one particular aspect 7 Bar.The domed cap 304 has, optionally, an inlet 305 with a supply hose 306attached thereto which in one particular aspect has a 52 mm ((two inch))diameter) for applying compressed gas (e.g. air and/or nitrogen and/oranother inert gas to the vessel to facilitate the movement of drillingcuttings from the vessel. Alternatively, cuttings may be introduced tothe inlet 305 by any known system, e.g. but not limited to, a conveyorsystem. The domed cap 304 is also provided with a cuttings inlet 307provided with a valve 308 (e.g. a gate valve or a full bore ball valve,which may be manually operable or operable remotely, e.g. using astepper motor.

The cuttings inlet 307, in one particular aspect, has an internaldiameter of 125 mm (5 inches). The planar base 303 has an opening 309.The opening 309 may be any suitable shape as viewed from above and, asshown, is generally rectangular. A tube 310 has an opening correspondingto and fixed to the perimeter of the opening 309 in the planar base 304to form a pressure tight seal. The tube 310 may be welded or otherwiseformed with the planar base 304. The tube 310 houses an optional augerapparatus which, in one aspect, is a screw conveyor 311 rotatablymounted in the tube 310 and driven by a variable speed hydraulic motor312.

The motor may alternatively be an electrical, petrol drive, pneumatic orotherwise powered motor. The screw conveyor has a shaft 313 and ahelical blade 314. The helical blade 314 has, in one aspect, a diameterof between 150 mm and 600 mm (6 and 24 inches), and in one particularaspect has a diameter of between 350 mm and 400 mm (fourteen and sixteeninches). The shaft 313 has a first end coupled to the variable speedhydraulic motor 312 and a second end rotatably arranged in a bearing 315in an end wall 316 of the tube 310. The tube 310 extends beyond theperimeter of the planar base 304. The helical blade 314 extends alongsubstantially the entire diameter of the planar base 304 and extendsinto a portion of the tube 310 which extends beyond the perimeter of theplanar base 304, whereupon the helical blade ends. In certain aspects inwhich there is no auger apparatus or no conveyor 311, positive pressuregas in the vessel feeds the material in the vessel to the dischargeopening.

Four, six or more radially projecting fingers 317 (two shown) extendingfrom the shaft 313 (or which may be connected to the interior of thetube 310) are spaced from the end of the helical blade 314. The portionof the tube 310 which extends beyond the perimeter of the planar base304 has a box 318 with a lower chamber 318 a, having a compressed gassupply inlet 319 arranged below the end of the helical blade 314. Theair supply inlet 319 is directed into the lower chamber 318 a of the box318 and in line with a cuttings outlet 320. The cuttings outlet 320 has,in one particular aspect, an internal diameter of 125 mm (5 inches) andis attached to a cuttings conveying line (not shown) of the same orsimilar internal diameter, which may be a flexible hose or a rigid pipe.

A sliding frame 321 is arranged inside the pressure vessel 302 on theplanar base 304 about opening 309. The sliding frame 321 may be anydesired shape as viewed from above which assists in moving drillingcuttings to the opening 309. In one aspect as shown, the frame 321 hastwo symmetrical curved members 322 and 323 forming an eye shape which isarranged on four arms 324 joined to a central member 325. The curvatureof the two symmetrical curved sections is slightly less than thecurvature of the perimeter of the planar base 304. Outer edges 327 ofthe two symmetrical curved sections 322 and 323 and of the four arms 324are, in one aspect, chamfered, whereas internal edges 328 (see FIG. 17A)facing the opening 309 are at right angles to the plane of the planarbase 304. The curved members 322 and 323 have flat bottoms 329. Theangle of the chamfer in certain aspects is between 45 and 20 degreesfrom the flat bottom 29. This can be seen clearly in FIG. 17A. It iswithin the scope of the present invention to have a frame or membersized and configured for movement across the opening 309 of any desiredshape, e.g., but not limited to, a member 402 as shown in FIG. 13C or agenerally circular frame, as shown with the frame 321 a, FIG. 13D. Theopening 309 may be any desired shape with any desired width and length;and, as shown, may be about the same width as an auger apparatus locatedbeneath the opening (or the auger apparatus may be slightly wider thanthe opening).

A hydraulically actuated piston and cylinder assembly 326 is joined atone end to the wall or planar base 304 of the pressure vessel 302 andthe other to the sliding frame 321, to induce movement of the slidingframe 321 over the planar base 304 backwards and forwards as indicatedby the arrow within the confines of the pressure vessel 302.Alternatively some of the frame movement apparatus may be positionedexteriorly of the vessel.

The curved members 322 and 323 may have various profiles to accomplishthe function of sliding underneath the drill cuttings 331 when movingaway from the opening 309 and acting as a rake or scoop to scoop, dig,or move the drill cuttings into the discharge opening 309. In one aspectthe space around the conveyor 311 in the tube 310 is maintainedsubstantially full to facilitate maintenance of a consistent dosing ratedependent on the rpm's of the conveyor 311 while conveying drillcuttings from the storage vessel.

An exemplary, but not exclusive, list of alternatives for the curvedmembers is shown in FIGS. 17A-17D. FIG. 17B shows a curved member 322(the member 323 is similar) having a chamfered front face 331 and aconcave rear face 330. FIG. 17C shows a curved member 322 (or 323)having a chamfered front face 323 and a stepped rear face 333 having ashoulder 334. FIG. 17D shows the curved member 322 (or 323) having astepped front face 335 and a slightly angled rear face 336 such that anacute angle is formed in use between the angled rear face 336 and theplanar base 304.

The storage vessel 301, in one aspect, is attached to a skid (not shown)to facilitate transport of the storage vessel on lorries, supply boats,train cars and on offshore and onshore rigs. The height of the storagevessel 301, in one particular aspect, when mounted on the skid is 3.26m, the length of the skid is 3.95 m and the width of the skid is 2.9 m.

A pressure relief valve 308 a is provided on the pressure vessel 302,which is set to between 10% and 20% above the normal working pressure ofpreferably 7 Bar. A removable and/or openable hatch (308 b) is,optionally, also provided in the wall of the pressure vessel 302 toallow access for inspection, servicing and cleaning.

FIG. 13C illustrates a rake system 400 according to the presentinvention useful instead of the sliding frame 321 and its associatedmovement apparatus. Like numerals indicate like parts in the systems ofFIGS. 13A and 13C. The system 400 (or the sliding frame 321, etc.) canbe used with any tank or vessel described herein. The system 400 has amember 402 on a shaft 404 that is moved back and forth above the opening309 by movement apparatus 410. A mover 412 (e.g. any suitable motorengine, or reciprocating mechanism, e.g., but not limited to, apiston/cylinder assembly like that of FIG. 13A) moves the shaft 404 backand forth to move the member 402 above the opening 309 to facilitate themovement of drilled cuttings down into the opening 309. Optionally avibratory apparatus 414 exterior to the vessel 302 vibrates the shaft404 to vibrate the member 402 and/or to induce vibration through thevessel 302 in the drilled cuttings. Optionally, a vibratory apparatus406 is disposed within the vessel 302 on the shaft 404 to vibrate theshaft 404 and the member 402 to facilitate cuttings movement. Optionallya vibratory apparatus 408 on the member 402 facilitates cuttingsmovement.

Referring to FIG. 14, wet drill cuttings are produced by a bank of shaleshakers 350 on a drilling rig. 349. The screened wet drill cuttings fallfrom the screens of the shale shakers into a ditch 348. The wet drillcuttings are moved along the ditch 348 using a screw conveyor or beltconveyor or fall directly into a hopper. Wet drill cuttings areoptionally fed into a dryer (not shown), such as a vortex dryer or adryer of the type disclosed in GB-A-2,297,702, the disclosure of whichis incorporated for all purposes herein, to remove a substantial amountof moisture. This is disclosed in more detail in co-pending PCTapplication number PCT/GB2004/000762 and in co-pending U.S. applicationnumber U.S. Ser. No. 10/764,825 filed by the applicant for the presentpatent, the disclosures of which are incorporated fully for all purposesherein. In some circumstances, the moisture content of the drillcuttings is reduced to between 1% and 5% moisture by weight and in othercircumstances down to 1% moisture by weight. Typically, “wet” cuttingscontain 5% or more oil content and “dry” cuttings contain less than 5%oil content.

The wet or dry drill cuttings fall directly into a hopper 351 of a blowtank 352, shown in more detail in FIG. 15A. The blow tank 352 may be ofthe type disclosed in GB-A-1,564,311, the disclosure of which isincorporated fully herein for all purposes. A valve 353, which may be ofthe type disclosed in GB-A-1,539,079, the disclosure of which isincorporated fully herein for all purposes, is arranged between thehopper 351 and a small pressure vessel 354 having a capacity, in oneaspect, of approximately 0.3 cubic meters, although the capacity inother aspects is between 0.1 and 1 cubic meter; or larger or smaller.The size of the small pressure vessel, in certain embodiments, isdependent on the space available near shale shakers, and/or the numberof cycles needed to transfer material, e.g. at a rate of 30 metric tonsper hour. The small pressure vessel 354 has a frusto-conical portion355. An air inlet 356 is arranged in an upper part of a wall of thepressure vessel 354 and a cylindrical portion 357 of circularcross-section is arranged between the valve 353 and the wall of thefrusto-conical portion 355, leaving a small gap 358 therebetween throughwhich air under pressure can pass from the air inlet 356 into thefrusto-conical portion 355. This aspect is also disclosed in U.S. Pat.No. 3,586,383 in the name of William Trythall, the disclosure of whichis incorporated fully herein for all purposes. A further valve 359(which is optional) is arranged at the discharge end of thefrusto-conical portion 355 between the small pressure vessel and a feedline 360. The further valve 358 may be of the same type as valve 353.The feed line 360 may be a flexible hose or a rigid pipe and, in oneaspect, has an internal diameter of 125 mm (5 inches).

In one aspect, the valve 353 and the further valve 359 cyclesubstantially out of phase, such that the valve 353 is open to allow thesmall pressure vessel 354 to be charged with drill cuttings undergravity from the hopper 351 while the valve 359 is closed to inhibitdrill cuttings from entering the feed line 360. The valve 353 is closedso that a dose of drill cuttings is trapped in the small pressure vessel354. The further valve 359 is opened. In one aspect air under pressureat between 1 and 8 Bar passes into the small pressure vessel 354 throughgap 358 and applies a positive pressure to the top of the charge ofdrill cuttings to push a dose of drill cuttings out into the feed line360. The further valve 359 may have a slight delay in opening to allowpressure to build up in the small pressure 354 vessel before beingopened. The frusto-conical portion 355 may be at an angle to induce massflow, as is well-known in the prior art, e.g. as disclosed in U.S. Pat.No. 3,604,758, the disclosure of which is incorporated fully herein forall purposes. Alternatively the interior wall of the frusto-conicalsection is lined with a friction reducing material, such as plastic,fiberglass, PTFE or a paint or enamel. The frusto-conical portion 355may alternatively be a chisel, pyramid, wedge, transition or squareopening type. Substantially all of the dose is discharged into the feedline and then the cycle is repeated. Many cycles per minute may occur.The feed line 360 leads to the inlet 307 of the storage vessel 301,which is arranged on the offshore rig 349 or, if it is a land based rig,near the rig. for example within 100-300 meters, although it may be upto many (e.g. three or more) kilometers away.

In use, the storage vessel 301 is vented to atmosphere, either using avalve or by disconnecting the air supply line 306 from the air inlet305. Doses of drill cuttings enter the storage vessel 301, through thefeed line 360 from the blow tank 352 and gradually fill the storagevessel 301. The storage vessel 301 can, in one aspect, store up totwelve cubic meters of drill cuttings, cut may, in other aspects, besized to store between five and 20 cubic meters. Once the storage tank301 is full or near full, a valve (not shown) in the feed line isoperated to divert the doses of drill cuttings to another storage vessel361. Alternatively, the feed line is disconnected from cuttings inlet307 and connected to the cuttings inlet on a further storage vessel 361.Several storage vessels may be arranged to form a bank 362 of storagevessels.

At a convenient time when the supply boat or vehicle to transport thedrill cuttings is in close proximity to the bank of storage vessels 362,for example when a supply boat 364 is moored to or within three or fourhundred meters of the offshore rig, one end of a flexible hose 363 isconnected to one of the storage vessels 301, 361. The other end of theflexible hose 363 is connected to at least one storage vessel 365 in abank of storage vessels 366 on the supply ship 364. The storage vessels365 are, in one aspect of the type described with reference to FIGS.13A-13C. Floatation collars 367 may be provided on the flexible hose 363to inhibit the hose from sinking into the sea.

An air supply provided by a compressor (not shown) under approximately 7Bar is provided through air supply hose 306 through air inlet 305 into aspace in the pressure vessel 302 provided above the surface of the drillcuttings. The variable speed hydraulic motor 312 is activated to drivethe screw conveyor 311. A supply of air, e.g. under approximately 7 Baror slightly less, is supplied through an air supply inlet 319 in the box318. A slightly lower pressure in the lower chamber 318 a of the box 318than the pressure applied above the drill cuttings facilitates movementof drill cuttings from the pressure vessel 302 into the screw conveyor311. The hydraulic piston and cylinder 326 is activated to move thesliding frame 321 backwards and forwards to facilitate movement of thedrill cuttings into opening 309. The chamfered edges on the sides of themembers 322, 323, 324 of the sliding frame 321 ensure that upon movementaway from the opening 309 the components of the sliding frame slideunder the drill cuttings and upon movement towards the opening 309, theopposed right angle or scoop profile surfaces pull the drill cuttingstowards the opening 309. The drill cuttings move through opening 309into the screw conveyor 311 which moves the cuttings along towards thelower chamber 318 a of the box 318. Towards the end of the screwconveyor, a double helix blade may be arranged to facilitate break up ofthe drill cuttings. Fingers 317 are also provided to facilitate break upof the drill cuttings which then fall into the box 318 and are propelledthrough the opening 320 into flexible hose 363 into storage vessel 365on the supply boat 364.

The supply boat then transports the loaded bank of storage vessels 366to shore. The storage vessels may be lifted off the supply boat 364 andplaced on train cars, flat bed lorries or directly into a processingplant. Alternatively, the drill cuttings can be discharged in the sameway as described above in relation to moving the cuttings from anoffshore rig to the supply boat 364.

An alternative dosing vessel 370 is shown in FIG. 16 which may be usedin place of the blow tank shown in FIG. 15A. The vessel 370 has acuttings inlet 371 leading from a hopper or other vessel (not shown),into a pressure vessel 372 through a fill valve 373. The lower end ofthe pressure vessel 372 is provided with a frusto-conical portion 374which leads to a discharge opening 375. The discharge opening isprovided with a discharge valve 376 for selectively opening or closingthe opening 375. The discharge valve 376 and the fill valve 373 are in afixed relationship by a piston 377 which extends from the dischargevalve 376 through the fill valve 373 to an actuating cylinder 378. Thepiston 377 may be actuated pneumatically, hydraulically or using astepper motor to open and close the fill valve 373 and the dischargevalve 376, which are arranged so that they operate substantially out ofphase. An air supply inlet 381 is arranged in the top of the smallpressure vessel 372 for supplying air under pressure, e.g. ofapproximately 7 Bars, although it may be supplied at a pressure betweenone and ten Bars. Aeration ports 379 are provided in the wall of thefrusto-conical portion 374 to inhibit sticking of the drill cuttings tothe walls and to inhibit bridging of the drill cuttings around thedischarge opening. Bristles 380 extend radially from the piston 377within the small pressure vessel 372, which are moved up and down inconcert with the valves to brush any drill cuttings stuck to the wallsor in the form of a bridge about the discharge opening (but for thebristles 380 the tank 370 is like a prior art tank).

In use, the fill valve 373 and the discharge valve 376 cyclesubstantially out of phase, such that the fill valve 373 is open toallow the small pressure vessel 372 to be charged with drill cuttingsunder gravity from the hopper 351 while the discharge valve 376 isclosed to inhibit drill cuttings from entering feed line 360. The fillvalve 373 is closed so that a dose of drill cuttings is trapped in thesmall pressure vessel 372. The discharge valve 376 is opened byactuation of the piston 377, which closes the fill valve 373. Air underpressure, e.g. at between 1 and 8 Bar, passes into the small pressurevessel 372 and applies a positive pressure to the top of the charge ofdrill cuttings to push a dose of drill cuttings out into the feed line360. The valves may cycle several times per minute with a relativelysmall pressure vessel. With a pressure vessel of 0.3 cubic meters, thevalves will cycle once or twice every minute or every two minutes. Thefeed line 360 (as in FIG. 15A) leads to the inlet 307 of the storagevessel 201, which is arranged on the offshore rig 349 or, if it is aland based rig, near the rig, for example within 300 meters although itmay be up to three or four kilometers away. Venting is provided asneeded via a vent line 382.

This type of dosing vessel 370 was manufactured by Klockner-Becroit andshown and described on pages 290-291 of the text book entitled“Pneumatic Conveying of Solids—a theoretical and practical approach” byKlinzing and Marcus, published in 1997.

As does the system according to the present invention shown in FIG. 11,FIG. 18 illustrates a system 450 according to the present invention andalso provides improvement to systems and apparatuses as disclosed in:U.S. Pat. No. 6,702,539 issued Mar. 9, 2004; Great Britain ApplicationNo. 9913909 filed Jun. 16, 1999; U.S. application Ser. No. 10/018,124filed as application PCT/GB00/02158 on Jun. 14, 2000; and EuropeanPatent EP 1,187,783 B1, published Sep. 24, 2003. The system 400 can beused in the system 200, FIG. 11.

Drilled cuttings flow in a pipe 457 into containers 451. Each container451 has a lower conical-shaped portion 455 with a lower opening 457.Adjacent each opening 457 is an apparatus 460 (which is like anyapparatus or system disclosed herein to facilitate the movement ofdrilled cuttings from a tank or vessel, e.g., but not limited to, thesystems disclosed in FIGS. 13A-13C, e.g. with a movable frame 324 and/ora movable member 402 and the associated powered movement mechanisms. Theapparatuses 460 move drilled cuttings into a pipe 459 (e.g. like thepipe 19, U.S. Pat. No. 6,702,539) from which the drilled cuttings can beintroduced into any suitable tank or container for transport, thecontainers 211, 231 of FIG. 11 and/or the containers 31 of U.S. Pat. No.6,702,539 may have an apparatus like the apparatus 460 to facilitatecuttings movement.

FIGS. 15B-15D illustrate a pressurized feeder 470 to feed cuttings (e.g.from shakers or dryers to storage vessels) in methods according to thepresent invention which have a pressure vessel 472 with a non-conicallower portion 474 which has two sloping sides 475. In certain aspectsthe pressure vessel 472 has a capacity of between 0.15 cubic meter and 1cubic meter, and in one particular aspect 0.33 cubic meter. Drilledcuttings enter the pressure vessel 472 from an upper inlet hopper 476through an opening 477. An inlet valve 478 (e.g. a dome valve)selectively controls the entry of drilled cuttings into the pressurevessel 472 and, in one aspect, provides a preselected dose of drilledcuttings, e.g., in one aspect 0.15 cubic meter to 1 cubic meter, and inone particular aspect 0.3 cubic meter.

Optionally, compressed gas (e.g. air and/or nitrogen or another inertgas) may be introduced into the vessels 451 with or after drilledcuttings flow into the vessels 451 in the line 457. Optionallycompressed gas is introduced in a line 461 into the vessels 451 forapplication to and/or above the drilled cuttings as previously describedand/or referred to for any embodiment described herein. Optionallycompressed gas is applied in lines 462 to the apparatuses 460 asdescribed above in the system of FIG. 13A. Optionally, compressed gasmay be applied to the interior of the line 459 with one or moreapparatus 463 to facilitate the flow of the drilled cuttings materialthrough the line 459. Each apparatus 460 may, optionally, have amovement member (e.g. like frame 321 or member 402) to facilitatemovement of drilled cuttings from the vessels 451. Optionally, amovement member 482 (e.g., like the movement member 402 or frame 321described above) is movable by movement apparatus 484 (shownschematically; e.g. any movement apparatus disclosed herein) tofacilitate the movement of drilling cuttings to and through the opening479 and from the vessel. Optionally, an auger apparatus 480 (e.g. as anyauger apparatus described herein and, in one aspect, like the conveyor311, FIG. 13A) may be used with the vessel 422.

FIGS. 19C-19E show a vessel system 500 according to the presentinvention which has a pressure vessel 502 (e.g. like the vessel 302,FIG. 13A) with a domed top 504, a generally cylindrical side wall 506,and a floor 508. Drilled cuttings 520 are fed into the vessel 502 via aninlet 510 flow through which is controlled by a valve 512. Optionally,compressed gas is introduced through a gas inlet 514.

A frame 530 (e.g. similar to the frame 321, FIG. 13A) slides over thefloor 508. The frame 530 includes a solid closure portion 532, but whichmay be perforated or made of screen. The closure portion 532 selectivelycloses off an opening 534 in the floor 508 which is located above ascreen conveyor 536 (like the conveyor 311, FIG. 13A) which is rotatablymounted in a tube 540.

As shown in FIG. 19A the closure portion 532 closes off flow to theconveyor 536 when movement apparatus 550 is in the fully retractedposition. This closed position is assumed when the storage vessel 500has drill cuttings being stored therein, for inhibiting drill cuttingsfrom sitting in the screw conveyor tube 540. It is possible if drillcuttings sit in the screw conveyor for too long a period of time thatthe drill cuttings can set and inhibit or prevent the screw conveyorfrom rotating when discharging the drill cuttings commences. This closedposition is also assumed when the storage vessel 500 is empty so thatdrill cuttings are inhibited from falling into the screw conveyor andbecoming compacted in the screw conveyor. As shown in FIG. 19B, theframe 530 has been moved by the movement apparatus 550 (like anymovement apparatus disclosed herein) and the opening 534 is no longerblocked and receives material flowing down from the vessel 502. Cuttingsflow from the vessel 502 to a cuttings discharge end 542 of the tube 540is facilitated by the screw conveyor 536.

As shown in FIGS. 19C and 19D the system 500, optionally, includes aplurality of aeration nozzles 561 through the floor 508 which inject gasunder pressure into the vessel 502 (in certain aspects, upwardly and/ordownwardly into the conveyor 536). The same compressed gas system thatprovides gas to the inlet 514 may be used to provide gas to the nozzles561 or a separate compressed gas source may be used. The pressurizedfluid through the nozzles 561 may be at a pressure higher than thepressure used to convey the drill cuttings. By applying a pneumaticfluid through the air nozzles 562 the drill cuttings are aerated. Thisis important when dry drill cuttings are stored in the pressure vessel502. The dry drill cuttings are aerated and moved out through the screwconveyor 536. When the drill cuttings are aerated, they act more like afluid and, therefore, transportation of the drill cuttings is morepredictable. This also can facilitate removal of blockages in theconveyor and may also be used to purge and clean the screw conveyor 536at any convenient time, such as when the storage vessel 500 is empty.Optionally, the system 500 includes a plurality of aeration nozzles 562which project into the tube 540 and provide gas under pressure into thetube 540 to promote cuttings movement, to inhibit cuttings consolidationand unwieldy slug formation. In one particular aspect there is aplurality of aeration nozzles along the full length of the tube 540.When the closure member 532 is in a closed position, air diffuses pastthe edges of the closure member 532 (and, if it is perforated, throughany perforations therein) and aerates the cuttings which are moving pastthe frame 530.

As shown in FIG. 19E by arrows 563, the conveyor 536 can be run inreverse to circulate cuttings within the vessel 502 to produce a morehomogenized mass of cuttings. The arrows 564 indicate rotation of theconveyor 536 in the direction resulting in cuttings moving from thevessel 502.

Optionally, the tube 540 may have an inclined end plate 547 tofacilitate cuttings movement toward the conveyor 536 and, when theconveyor is run in reverse, to facilitate cuttings movement into andwithin the vessel 502. Optionally, the tube 540 has an inclined endplate 548 near the tube's discharge end which urges material down into adischarge chamber 545 and out of the tube 540. Optionally, compressedgas is supplied to an inlet 543 to promote the movement of cuttings fromthe discharge chamber out the discharge end 542 of the tube 540.

A sliding frame (e.g. like the frame 530, FIG. 19A) in dealing with wetcuttings, dry cuttings, or cuttings which are moisture bearing, providesdischarge rate control (from the discharge end 542) by controlling theamount of material that flows into the conveyor 536. Aerating driedcuttings, e.g. cuttings dried by a dryer facilitates cuttings movementby making the cuttings act more like a fluid and makes transportation ofthe cuttings more predictable.

Compressed gas to facilitate cuttings conveyance is supplied from acompressed gas source 602 in a line 627 (with flow controlled by a valve616) to a vessel 622 and in a line 612 (with flow controlled by a valve615) to a discharge box 624. Cuttings discharged from a tube 626 of thesystem 620 are propelled by the gas into and through a conveying line632 from which the cuttings flow to further processing apparatus (e.g.another vortex dryer) or to storage (e.g. cuttings boxes on a rig, onshore or on a boat).

A plurality of pressure monitors 640 are spaced-apart along theconveying line 632, each including a pressure gauge and in communicationwith a control system, e.g. a PLC control system 680. A plurality of gasinjection apparatuses 690 are spaced-apart along the conveying line 632for selectively injecting gas under pressure into the conveying line 632as directed by the PLC controller 680. Gas is supplied in a line 613 tothe apparatuses 690. A valve 614 controls flow in the line 613. Thevalves 614, 615, 616 are in communication with and controlled by the PLCcontroller 680. A conveyor 631 of the system 620 is in communicationwith and controlled by the PLC controller 680.

Each apparatus 690 includes a one way check valve 691 through which airflows into a conveying line 632, the one way check valves 691 inhibitingdrill cuttings from entering and blocking pneumatic line 613; acontrollable valve 692 that selectively controls flow of fluid into theconveying line 632; and a regulating valve 693 that selectively allowspneumatic fluid under pressure through and into the conveying line 632when the pressure differential between the line 613 and the pressure atthe point 640 is less than a predetermined difference in order tomaintain a constant pressure drop along the conveying line.

FIG. 20A shows a system 600 according to the present invention forstoring and moving drilled cuttings (which may be wet, dry, ormoisture-bearing ((damp))) which has a vortex dryer 610, feeder system620, and a conveying system 650. The feeder vortex dryer 610 providesdrilled cuttings to the feeder system 620. The feeder system 620 has avessel 622 which provides drilled cuttings to the conveying line 632.The feeder system 620 may be, in certain aspects, like the systems ofFIG. 15B or 16 or like any blow tank or storage vessel disclosed herein.

The monitoring and control system maximizes throughput in a safe manner,i.e. avoiding plugging and pushing solids into a conveying line in anuncontrolled manner. The use of the apparatus 690 and 640, in oneaspect, ensures that the cuttings are kept “live” and moving within theconduit 632. The pressures are monitored at strategic points along itsfull length. The pressures observed are maintained by modifying thecuttings feed rate and/or assist air flow for continuous (and, in someaspects, optional) performance. To minimize the overall pressure dropover the length of the conduit 632, the length and/or density of aconduit 632 is controlled which is in the dense phase mode of flowwhereby it has filled the entire cross section of conduit 632. Thedenser the slug, the higher the wall friction, hence the higher thepressure required to propel the slug down the conduit 632. Also therelationship of slug-length-to-pressure required to propel a slug isexponential; i.e., the pressure required to convey a series of slugsseparated by “cushions” of air is far less than that needed to convey asingle slug whose length is equivalent to the sum of the lengths of theseries of slugs.

The system 620 doses cuttings into the conduit 632 in slugs, the size ofwhich are determined by the screw or auger outside diameter, shaft sizeand pitch. The feed rate is directly proportional to the rotationalspeed of the screw. Localized aeration within the conveying/dischargechamber of the screw ensures the cuttings are “life” and the speedcontrol/stop/start facility of the screw controlled by the PLCcontroller 680 offers close control in the creation of the slugs. Thiscontrol is based upon the pressure regime within the conduit 632 whichis heavily dependant upon the mode of flow.

In one aspect nominal setpoints are used within the conduit 632regarding the maximum pressure drop across the conduit 632, one set at alow value for dilute phase, e.g. 2 bar, which is used for dried drillcuttings and the other for non-dried cuttings which is higher, e.g. 4bar. In one particular aspect, in dense phase, the drill cuttings movealong the conveying line at approximately 10 m/s; and in lean or dilutephase, the drill cuttings move along the conveying line at approximately30 m/s. The PLC controller 680 ramps up the screw speed to the speednecessary to feed the conveying line 632 so that pressure drop ismaintained to a set level between the units 690. For example, with fourunits 690 spaced equidistant along the length of a straight conveyingline 632, the conveying line 632 is dosed with a first dose of drillcuttings from the feeder 620. The air supply 602 is activated and theplug of drill cuttings moves along the conveying line. The initialpressure is set to e.g. 4 bar and it is expected that the pressure atthe end of the conveying line will be slightly above atmospheric whenthe plug reaches the end. The units 690 regulate the pressure in theline so that there is a reasonably constant pressure drop between theunits 690. The pressure drop is, e.g. 0.5 bar between each unit, suchthat after the first unit 690 the pressure is regulated at 3.5 bar,after the second unit the pressure is regulated to 3 bar after the thirdunit the pressure is regulated to 2.5 bar and after the fourth unit thepressure is regulated to 2 bar so that it is expected that the pressureat the end of the conveying line 632 is approximately 1.5 bar and thatthere is a reasonable degree of certainty in knowing the plug willdischarge from the end of the conveying line and into a storage vessel.If the pressure drop is within a certain percentage, e.g. 30%, and, inone aspect, 15%, and in one particular aspect, 10% of what was expected,the regulator opens the line 613 and allows air under pressure,regulated by regulator 693 to enter the conveying line at the correctpressure.

A standard PID loop “PID loop” is utilized such that should the pressuredrop overshoot the desired setpoint, the screw feeder speed is reducedor stalled accordingly. Feedback from the pressure monitors 640 alongthe line which are located strategically slightly upstream ofbends/vertical lifts or any other areas known to create turbulencewithin the conduit are used in order to actuate air assist valves in theapparatus 690 should it be necessary. An air assist valve is located ata turbulence point downstream of a pressure monitor and should thepressure at the monitor go below a given percentage value compared tothe sensor immediately upstream of it, e.g. 80%, then air is fed directfrom source 602 via the bypass line 613 which runs the full length ofthe conduit 632 into the associated assist point. The pressure settingfor the air assist is set at e.g. 90% of the pressure value at themonitor 640 immediately upstream, and if this pressure is reached, thenthe assist air is also directed to the next injection point immediatelydownstream and so forth. Each valve 691 can feed an associated gasinjection nozzle 699 (e.g. see FIG. 20B).

FIGS. 21A-21C illustrate a system 700 according to the present invention(like the system of FIG. 15B, but with a vibratory motor for a hopper)which has a feeder system 720, a storage vessel system 740, and acontrol system 760 in communication with the systems 720, 740. Thesystem 720 has a buffer hopper 721; an optional vibratory motor 722 forvibrating the hopper 721 and its contents; an expansion joint 722; and avalve 723 at an exit opening 724 to control the flow of drilled cuttingsfrom the hopper 721 to the storage vessel system 740. The system 700 isused, e.g., to move drilled cuttings from shakers to storage vessels,and, in one particular aspect, the pressure vessel 740 only has astorage capacity of about 0.3 cubic meter.

The storage vessel system 740 may be like the storage systems of FIGS.13A, 15B-D, 19A and 20A. The system 740 has a vessel 742 which receivesdrilled cuttings through an inlet 743. A vent valve 744 selectivelyvents the vessel 742 and a relief valve 745 relieves pressure in thevessel 742 at a preset level. A conveyor 750 conveys drilled cuttingsfrom the vessel 742 to a discharge box 751 and the cuttings exit adischarge end 752 of a tube 753 to flow into a conduit (not shown; e.g.like the conduit 632, FIG. 20A). A motor/gear system 760 rotates theconveyor 750.

Compressed gas from a source 770 supplied gas under pressure in a line771 to an inlet 772 on the tube 753; in a line 773 to an inlet 774 atthe discharge end 752 of the tube 753; in a line 775 to an inlet 776 atthe discharge box 751; and in a line 777 to an inlet 778 of the vessel742. Each line has a one way check valve 779. Optionally the hopper 721is mounted on isolation/non-vibration mounts 782.

All the operational components of the system 700 are in communicationwith (see dotted lines) a controller 760 (e.g. like the controller 680,FIG. 20A).

Each line 771, 773, 777 has an on/off flow control valve 771 a, 773 a,777 a respectively (e.g. like the valves 692); a pressure regulator 771b, 773 b, 777 b, respectively (like the pressure units 690; pressure setmanually or by the control system, the set pressure effectively sets themaximum working pressure of the system, e.g., 2 BAR for dried cuttingsor 4 BAR for wet cuttings from the shale shakers); and flow controlvalves 771 c, 773 c, and 777 c, respectively, which control the rate ofchange in pressure (e.g., may be needle valves, orifice plates, orsimilar devices).

Via the line 777 gas is provided to the vessel 742 at a pressure equalto the pressure of gas provided to the tube 753 in the line 771 and tothe gas provided in the line 773 to the discharge box 751 so that thepressure drop across the conveyor (screw feeder) 750 is negligible.Therefore feed rate of cuttings from the system 700 is determined by therpm's of the conveyor 750. In one aspect gas is input downstream of adischarge valve 752 a in the line 773. With the discharge valve 752 aclosed, the vessel 742 can be vented to the atmosphere, permittingrefilling of the vessel 742 while cuttings are being conveyed downstreamof the discharge end 752.

FIG. 22 shows a system 800 according to the present invention which hasa vortex dryer 801 which dries drilled cuttings. A conveyor system 802with augers 803, 804 driven by a motor/gear system 805 provides drilledcuttings selectively to a tank system 810 or to a pressurized feedersystem 820, based on measurements by a moisture sensor 821 (or sensors).Non-wet cuttings go to the system 820; if “wet” cuttings are sensed, theaugers are reversed and cuttings are conveyed to the tank system 810. Asensor (or sensors) 821 sense moisture content of the drilled cuttings.If the sensor 821 senses “wet” (e.g. greater than 5% oil content) thenthe auger is reversed and moves the cuttings to the “wet” cuttingsstorage vessel 810; and, if the cuttings are dry (e.g. less than 5% oilcontent), the auger is set in forward motion and the cuttings aresupplied to the feeder system 820, which blows the cuttings to a drycuttings box 825. In one particular arrangement, once cuttings havemoved to the storage vessel 810, they can then be moved to the drycuttings box 825. Optionally (as is the case for any moisture sensor orsensor apparatus in any system herein) the sensor 821 may have aprotective canopy 821 a for components outside a hopper and a protectivecanopy 821 b for components 821 c within a hopper 822. Such a canopy 821b protects sensor components 821 c from drilling cuttings fallingdownwardly in a hopper. Multiple sensors 821 may be used spaced apartaround the hopper 822 (as is the case for any system according to thepresent invention with moisture sensor apparatus). In certain aspects,such sensors are efficacious with a drilling cuttings amount that is atleast one inch thick and has an area of at least three to four squareinches. Such sensors may produce continuous readings for more accurateuse by a control system 829 which is in controlling communication withcomponents of the system 800 as indicated by dotted lines.

The control system 829 can switch cuttings flow from the system 825(e.g. for adequately dry cuttings) to the system 810 (e.g. forrelatively wet cuttings). In any system herein a first storage apparatusor a “dry” storage apparatus can be a storage vessel system, the hold ofa ship, or a hold or reservoir on a rig or in legs of a rig. Suchstorage facility, in whatever form, may have, according to the presentinvention, a positive pressure pneumatic system and a bottom aerationsystem for aerating drilled cuttings material from underneath thematerial (e.g. through a perforated bottom plate or member) producing adilute phase material which is more easily conveyed. In one particularaspect moisture content sensors are like Models MCT 300, MCT 600 and MCT101-T sensors from Process Sensors Corporation, Milford, Mass. As is thecase with any pressurized vessel in any system herein, a cuttings vessel820 a of the system 800 may be, in volume, between 0.05 m³ to 0.2 m³.

FIG. 23 shows a system 830 according to the present invention in which aconveyor system 831 powered by a motor/gear system 832 feeds drilledcuttings to two vortex dryers 833. Cuttings processed by the vortexdryers 833 are fed by conveyor systems 834 to a hopper 835 of a feedersystem 836 (like the system 820, FIG. 22). One of the vortex dryers 833has a screen which blinds if the drill cuttings are “near sized” (“nearsized” means the size of cuttings generated by drilling which have asize distribution like that of the size of screen mesh apertures ofscreens in screening apparatus; near size particles can become lodged inscreen apertures, clogging a screen), at which point wet drill cuttingsflow out of the vortex dryer. This is noted by a moisture sensor 831which sends a signal to the second vortex dryer, which kicks in, whichhas a screen with a screen size different from the first vortex dryer,and therefore can cope with this size of particle. The system 836produces processed cuttings which exit in a conduit 837.

FIG. 24 shows a system 850 according to the present invention similar tothe system of FIG. 23 which has a conveyor system 851 powered by amotor/gear system 852 which conveys drilled cuttings to vortex dryers853 which in turn feed dried cuttings to a system 856 (like the system836) which feeds the cuttings into an exit conduit 857. The vortexdryers 853 have hoppers 854 beneath them which feed the system 856.

FIG. 25 shows a system 900 according to the present invention for adrilling rig R in which drilled cuttings (e.g. from shale shakers,centrifuges) flow to a system 906 (like the systems 820, 836, 856) witha vortex dryer 907. The system 906 processes the cuttings and feeds themto a system 907 (like the systems 810, 820 and/or systems of FIGS. 13A,13C, 19A). From the system 907 the cuttings flow to a cuttings box on aboat B or to a system 908 (like the system 907) on the boat B.

FIG. 26 shows a system 920 according to the present invention in whichshakers 921 feed drilled cuttings material to a conveyor system 922(like the conveyor systems ((pressurized screen feeder systems)) ofFIGS. 22-24) which feeds the material to a vortex dryer 923 which feedsdried material to a pressurized screw feeder system 924 (like the screwfeeder systems of FIGS. 20A, 21A and 22-24). Material processed throughthe system 924 exits for transfer in a line 925. Fluid recovered fromthe vortex dryer 923 flows in a line 926 to a holding tank 927 fromwhich it is pumped by a pump 928 in a line 929 to a centrifuge 930.Solids from the centrifuge 930 are conducted in a line 931 for disposaland liquid is pumped in a line 932 to a holding tank 933. A pump 934pumps liquid from the holding tank 933 either in a line 939 to a mudreturn system 935 (with a valve 936 closed); or back to the vortex dryer923 in a line 937 (with a valve 938 closed).

FIG. 27 shows a system 950 according to the present invention in which apressurized screw feeder system 952 selectively feeds drilled cuttingsmaterial to dried cuttings storage systems 953 or to a “wet” tank system954. A wetness meter 955 senses moisture content of the drilled cuttingsmaterial and controller 960 in communication with the wetness meter 955,controls a diverter valve 956 so that adequately dry cuttings go to thestorage systems 953 with flow to the “wet” tank system 954 shut off; andwet cuttings go to the wet tank system 954 with flow to the storagesystems 953 shut off. Optionally, each storage system 953 has its ownassociated diverter valve 957 so that flow to each box is selectivelycontrolled by the controller 960.

In certain aspects the pressurized screen feeder system 952 is like thesystems in FIGS. 20A and 26; the wet tank system 954 is like the wettank systems in FIG. 22; and the storage systems 953 are like thestorage systems in FIGS. 13B, 15B and 22. The controller 960 controlsthe motors of each conveyor in the system 950.

In each of the systems of FIGS. 22-27 a suitable control system controlsthe various components and is in communication with the moisturesensors, valves, conveyors, and motors.

The present invention, in certain aspects, provides a vessel forselectively holding drilling cuttings material, the vessel having abody, the body having a hollow container with an interior space forreceiving drilling cuttings material and from which drilling cuttingsmaterial may exit from the body; a first opening through which thedrilling cuttings material is introducible into the hollow container; asecond opening through which the drilling cuttings material is passableout from the hollow container; movement apparatus, the movementapparatus having a movement member within the hollow container andmovable adjacent the second opening to facilitate passage of thedrilling cuttings material into the second opening; and an exit openingthrough the body through which drilling cuttings can exit from thehollow container. Such a vessel may include one or some (in any possiblecombination) of the following: an inlet in the body through whichcompressed gas (e.g. air and/or nitrogen) under pressure is flowableinto the body to facilitate the passage of the drilling cuttingsmaterial through the body; the movement apparatus having power apparatusconnected to the movement member for moving the movement member; whereinthe second opening has a length and the movement member has an elongatedmember with a length substantially equal to the length of the secondopening; wherein the second opening has a width and the movement memberis movable back and forth across said width; wherein the movement memberhas a frame comprising a control shaft connected to a generally circularshaped outer perimeter portion and at least one cross-member; whereinthe outer perimeter portion of the frame is generally eye-shaped;conveyance apparatus located below the second opening for conveyingdrilling cuttings material, the conveyance apparatus including a conduitfor receiving the drilling cuttings material passing through the secondopening; gas apparatus in fluid communication with the conduit forapplying compressed gas under pressure for facilitating the movement ofthe drilling cuttings material within the conduit; auger apparatuswithin the conveyance apparatus for auguring the drilling cuttingsmaterial along in the conduit; at least one projection member projectingfrom the auger apparatus to facilitate dispersal of the drillingcuttings material; the conduit having an exit portion, the exit portionhaving an exit portion inlet, flow apparatus for flowing compressed gasunder pressure into the exit portion inlet to facilitate exit of thedrilling cuttings material from the conduit; wherein the movement memberhas an edge shaped for facilitating movement of the drilling cuttingsmaterial to the second opening; wherein the body of the vessel has twosides which slope toward each other; wherein the body of the vessel hasa conical hopper portion; wherein the conical hopper portion has a coneangle and forms a lower section of the vessel and the cone angle isbelow a critical value required to achieve mass flow of the drillingcuttings material; wherein the body is generally cylindrical with agenerally circular base, the second opening extending through thegenerally circular base; positive pressure blow tank apparatus forfeeding the drilling cuttings material to the first opening; wherein thedrilling cuttings material is a free-flowing paste; wherein the drillingcuttings material is a non free-flowing paste; and/or moisture-contentsensor apparatus on the body for sensing moisture content of drillingcutting within the vessel, conduit apparatus for conducting drillingcuttings from the exit opening, valve apparatus for selectivelycontrolling flow of drilling cuttings in the conduit apparatus, and acontroller in communication with the moisture-content sensor and thevalve apparatus for selectively controlling flow in the conduitapparatus and, in one aspect, conducting drilling cuttings material to a“wet” tank or to a “dry” tank.

The present invention, in certain aspects, provides a vessel forselectively holding drilling cuttings material, the vessel having: abody, the body having a hollow container with an interior space forreceiving drilling cuttings material and from which drilling cuttingsmaterial may exit from the body; a first opening through which thedrilling cuttings material is introducible into the hollow container; asecond opening through which the drilling cuttings material is passableout from the hollow container; movement apparatus, the movementapparatus having a movement member within the hollow container andmovable adjacent the second opening to facilitate passage of thedrilling cuttings material into the second opening; an inlet in the bodythrough which compressed gas under pressure is flowable into the body tofacilitate the passage of the drilling cuttings material through thebody; the movement apparatus further comprising power apparatusconnected to the movement member for moving the movement member; whereinthe second opening has a length and the movement member comprises anelongated member with a length substantially equal to the length of thesecond opening; wherein the second opening has a width and the movementmember is movable back and forth across said width; and conveyanceapparatus located below the second opening, the conveyance apparatusincluding a conduit for receiving the drilling cuttings material passingthrough the second opening. Such a vessel may include one or some (inany possible combination) of the following: wherein the body of thevessel has two sides which slope toward each other; wherein the body ofthe vessel has a conical hopper portion and wherein the conical hopperportion has a cone angle and forms a lower section of the vessel and thecone angle is below a critical value required to achieve mass flow ofthe drilling cuttings material; and/or wherein the body is generallycylindrical with a generally circular base, the second opening extendingthrough the generally circular base.

The present invention, in certain aspects, provides a vessel forselectively holding drilling cuttings material, the vessel having: abody, the body comprising a hollow container with an interior space forreceiving drilling cuttings material and from which drilling cuttingsmaterial may exit from the body; a first opening through which thedrilling cuttings material is introducible into the hollow container; asecond opening through which the drilling cuttings material is passableout from the hollow container; conveyance apparatus located below thesecond opening for conveying drilling cuttings material, the conveyanceapparatus including a conduit for receiving the drilling cuttingsmaterial passing through the second opening, gas apparatus in fluidcommunication with the hollow container and with the conduit forapplying compressed gas under pressure within the hollow container andwithin the conduit so that pressure drop between the hollow containerand the conduit is negligible. Such a vessel may include one or some (inany possible combination) of the following: movement apparatus, themovement apparatus having a movement member within the hollow containerand movable adjacent the second opening to facilitate passage of thedrilling cuttings material into the second opening, and an exit openingthrough the body through which drilling cuttings can exit from thehollow container.

The present invention, in certain aspects, provides a system forprocessing drilling cuttings material, the system having a cuttingsfeeder system for receiving drilling cuttings material from a wellboreoperation; conduit apparatus for conveying drilling cuttings materialfrom the cuttings feeder system to first storage apparatus and to secondstorage apparatus; sensor apparatus for sensing moisture content ofdrilling cuttings material in the cuttings feeder system; valveapparatus on the conduit apparatus for selectively controlling flow tothe first storage apparatus and to the second storage apparatus; controlapparatus in controlling communication with the cuttings feeder system,the sensor apparatus, and the valve apparatus for selectively permittingflow of drilling cuttings material from the cuttings feeder system andthrough the conduit apparatus to either the first storage apparatus orthe second storage apparatus depending on sensed moisture content of thedrilling cuttings material sensed by the sensor apparatus; and thecontrol system permitting flow to the first storage apparatus whensensed moisture content is below a pre-selected valve and to the secondstorage apparatus when sensed moisture content is above the pre-selectedvalve. Such a system may include one or some (in any possiblecombination) of the following: wherein the first storage apparatusincludes a plurality of spaced-apart pressure vessel storage system,each with corresponding flow conduits for receiving drilling cuttingsmaterial, each with corresponding vessel valve apparatus for selectivelycontrolling flow in said corresponding flow conduits, each of saidvessel valve apparatuses in controlling communication with the controlapparatus; wherein the cuttings feeder system, the first storageapparatus, and the second storage apparatus each has associated cuttingsmovement apparatus, all cuttings movement apparatuses in controllingcommunication with the control system; and/or wherein the cuttingsfeeder system includes a cuttings vessel which receives the drillingcuttings material, the cuttings vessel in volume between 0.05 m³ and 0.2m³.

The present invention, in certain aspects, provides a method for movingdrilling cuttings material from a vessel, the method includingintroducing drilling cuttings material into a first opening of a vessel,the vessel like any herein according to the present invention, movingthe movement member of the vessel adjacent a second opening facilitatingpassage of the drilling cuttings material into the second opening; andin such a method the drilling cuttings material is a free-flowing paste;or is a non free-flowing paste.

The present invention, in certain aspects, provides a method ofconveying a paste, the paste including drilled cuttings laden withfluid, the method including: feeding the paste into a vessel, the vesselhaving a body, the body comprising a hollow container with an interiorspace for receiving drilling cuttings material and from which drillingcuttings material may exit from the body, a first opening through whichthe drilling cuttings material is introducible into the hollowcontainer, a second opening through which the drilling cuttings materialis passable out from the hollow container, and movement apparatus, themovement apparatus comprising a movement member within the hollowcontainer and movable adjacent the second opening to facilitate passageof the drilling cuttings material into the second opening; and applyinga compressed gas to the vessel to cause the paste to flow out of thevessel, the vessel including a conical hopper portion which, at leastduring discharge of the produced material, forms the lower section ofthe vessel and the lower section having a cone angle below a criticalvalue required to achieve mass flow of the produced material. Such amethod may include one or some (in any possible combination) of thefollowing: wherein the paste is a free-flowing paste; wherein the pasteis a non-free-flowing paste; accomplishing said method on a boat, oraccomplishing said method on an offshore drilling rig.

The present invention, in certain aspects, provides a method forprocessing drilling cuttings material, the method further including:introducing drilling cuttings material to a cuttings feeder system of acuttings conveyance system, the cuttings conveyance system having acuttings feeder system for receiving drilling cuttings material from awellbore operation, conduit apparatus for conveying drilling cuttingsmaterial from the cuttings feeder system to first storage apparatus andto second storage apparatus, sensor apparatus for sensing moisturecontent of drilling cuttings material in the cuttings feeder system,valve apparatus on the conduit apparatus for selectively controllingflow to the first storage apparatus and to the second storage apparatus,control apparatus in controlling communication with the cuttings feedersystem, the sensor apparatus, and the valve apparatus for selectivelypermitting flow of drilling cuttings material from the cuttings feedersystem and through the conduit apparatus to either the first storageapparatus or the second storage apparatus depending on sensed moisturecontent of the drilling cuttings material sensed by the sensorapparatus, and the control system permitting flow to the first storageapparatus when sensed moisture content is below a pre-selected valve andto the second storage apparatus when sensed moisture content is abovethe pre-selected valve; sensing moisture content of the drillingcuttings material in the cuttings feeder system with the sensorapparatus; controlling the valve apparatus with the control apparatus topermit flow of drilling cuttings material to either the first storageapparatus or the second storage apparatus depending on the sensedmoisture content of the drilling cuttings material in the cuttingsfeeder system by the sensor apparatus; and selectively flowing drillingcuttings material to the first storage apparatus and the second storageapparatus. Such a method may include one or some (in any possiblecombination) of the following: wherein the first storage apparatusreceives dry drilling cuttings material and the second storage apparatusreceives wet drilling cuttings material; wherein the cuttings feedersystem includes dryer apparatus for drying the drilling cuttingsmaterial from the wellbore operation, the method further includingdrying with the dryer apparatus the drilling cuttings material from thewellbore operation; and/or wherein the cuttings feeder system, the firststorage apparatus, and the second storage apparatus each has associatedcuttings movement apparatus, all cuttings movement apparatuses incontrolling communication with the control apparatus, the methodincluding controlling with the control apparatus the cuttings movementapparatus.

Referring now to FIG. 28, drill cuttings material from operations on adrilling rig DRG produced by a bank of shale shakers 1002 fall into aditch 1003. The material is moved to a vibrating hopper 1015.Optionally, the ditch 1003 has an auger or other conveyor (not shown)running therealong to move the material to the end of the ditch 1003.The wet drill cuttings material falls directly into a vibrating hopper1015 of a dosing apparatus 1000. The dosing apparatus 1000 feeds apneumatic conveying line 1006 through which the material is blown byapparatus 1008 to a bank 1007 of storage vessels 1019. In one aspect thedosing apparatus includes components as described in FIG. 29 below.Alternatively, the drill cuttings material is re-injected directly in toa well (CRI). The material is kept in the storage vessels 1019 as abuffer until a supply boat SBT arrives. A flexible pneumatic line 1009is attached to the bank 1007 of storage vessels 1019 and to a bank 1010of storage vessels 1013 on the supply boat SBT. Optionally, a screw orother conveyor associated with the storage vessels 1019 doses theflexible pneumatic line 1009 with drill cuttings material. Positivepneumatic pressure (supplied, e.g. by a rig pressure system or adedicated pressure system) in the flexible pneumatic line 1009 blows thedrill cuttings material into the bank 1010 of storage vessels on thesupply boat SBT.

The supply boat SBT then transports the bank 1010 of storage vessels1013 to another location or to shore. The storage vessels 1013 may belifted off the supply boat SBT and placed on train cars, flat bed trucksor lorries, or directly into a processing plant. Alternatively, thedrill cuttings can be discharged in any way as described above herein inrelation to moving cuttings from an offshore rig to a supply boat. Anycontrol system or apparatus described herein may be used with thevessels, apparatuses, and systems according to the present invention,including those of FIGS. 28-37C.

Referring to FIGS. 29-31, in one aspect the dosing apparatus 1000 has avalve 1101, which may be a spherical dome valve which an inflatable sealfrom Roto Disc Co. or of the type disclosed in GB-A-1,539,079, arrangedbetween the hopper 1015 and a chisel plane pressure vessel 1103 having,e.g., a capacity of approximately 0.33 cubic meters, although thecapacity may typically be between 0.1 and 1 cubic meter. Vibratorapparatus 1015 a selectively vibrates the hopper 1015. The vessel 1103has two converging sides 1104 and 1105, but may be configured as anyvessel disclosed herein. An air inlet 1106 is arranged in an upper partof a wall of the vessel 1103 for selectively receiving air underpressure through a conduit 1106 a from an air inlet AI. A screw feederor metering screw 1107 is arranged at the bottom of the converging sides1104 and 1105 in a housing 1102 integral therewith, which leads into areducer 1108. The reducer 1108 is provided with an air inlet 1109 in anouter wall 1110. Valve apparatus 1124 a selectively controls air flowthrough the inlet 1109. The air inlet 1106 facilitates pressureequalization across the screw when pressure is generated within thetransfer line by the conveying air through the valve 1124 a.

The air inlet 1109 is in fluid communication with an annulus 1111 formedby a flanged pipe stub 1112 and the outer wall 1110. The flanged pipestub 1112 has, in certain aspects, an inner diameter substantially equalto the inner diameter of the housing 1102 for the screw 1107, which, inone particular aspect, is about 30 cm (twelve inches). The annulus 1111has an annular opening 1113 formed by the end of the pipe stub 1112 anda converging wall 1113 a of the reducer 1108. A valve 1114 at theconverged end of the converging wall 1113 a is an on/off isolationvalve. The inner diameter of the converged end of the converging wall1113 a, in certain aspects, is 20 cm (eight inches) in diameter.

A further air inlet 1115 is provided in an outer wall 1116 having asubstantially concentric flanged pipe stub 1117 forming an annulus 1118therebetween. Valve apparatus 1124 b controls air flow in a conduit 1115a and through the inlet 1115. The flanged pipe stub 1117 has an innerdiameter substantially equal to the inner diameter of the converged endof the converging wall 1113. The annulus 1118 has an annular opening1119 formed by a converged end of the pipe stub 1117 and a convergingpart 1120 of outer wall 1116. The inner diameter of the end of theconverged outer wall, in certain aspects, is 125 cm (five inches) whichis connected to a conveying line 1014 which has, in one particularaspect, an internal diameter of 125 mm (5 inches) and may be a hose orrigid pipe. The conveying line 1014 may be in communication with storageapparatus and/or additional flow conduit(s).

In use, drill cuttings material from the ditch 1003 fall into the hopper1015. Valve 1114 is closed and the inlet valve 1101 is opened. The drillcuttings material falls from the vibrating hopper 1015 into the vessel1103. Inlet valve 1101 is then closed after a predetermined time or whenthe weight of the vessel 1103 has increased to a predetermined weight orwhen the height of the wet drill cuttings in the hopper 1015 hasdecreased by a predetermined amount, which, in one aspect is measured bya measuring device, e.g. an ultrasonic device, a radar device, or lasermeasuring device LM (shown schematically), which continually monitorsthe height of the wet drill cuttings in the hopper 1015.

The vessel 1103, in one aspect, now contains approximately 0.33 cubicmeters of wet drill cuttings. Air enters the inlet 1106 from a conduit1106 a in the vessel 1103 and through inlet 1109. A valve 1106 ccontrols flow to the air inlet 1106. The screw 1107 is then rotated byactivating a motor 1122 through a gear box 1123. Valve 1114 is openedand air inlet 1115 at an end of the conduit 1115 a is closed. Drillcuttings material is then dosed by the screw 1107 into the reducer 1108and blown through the valve 1114 and into the conveying line 1014. Apressure monitoring device 1109 a monitors the pressure at the inlet1109. A pressure monitoring device 1115 c monitors pressure at the inlet1115. A control system PD (shown schematically; in communication withthe pressure sensors), in one aspect, maintains the pressure at theinlet 1109, in one aspect at between 3.5 to 4 bar by altering the speedof rotation of the screw 1107 for conveying drill cuttings material. Ifthe pressure reading is too high, the speed of rotation of the screw1107 will be decreased; if the pressure is too low, the speed ofrotation of the screw 1107 will be increased. The drill cuttingsmaterial is conveyed along a conveying line (discharge pipework) 1014 inslugs by the screw 1107. In one aspect, slugs are between 0.5 m and 10 mlong. In certain aspects, one vessel 1103 full of drill cuttingsmaterial is discharged in one to fifty slugs. Once the vessel is empty,which is known by a monitoring the pressure at the sensor 1109 a orwaiting a predetermined time period, or by measuring a predetermineddecrease in weight of the vessel 1103, valve 1114 is closed, the airsupply through inlets 1106 and 1109 is stopped, and the air is divertedthrough the inlet 1115 to maintain pressure in the conveying line 1014and/or to assist in moving any still-remaining material into and downthe line 1014. Air pressure in the vessel 1103 is allowed to vent toatmospheric pressure through a line 1125 by activation of a valve 1126.The inlet valve 1101 is opened allowing more drill cuttings material tofall into the pressure vessel 1103 and the cycle is repeated.

The weighing of the vessel 1103 is carried out by load cells 1127 and1128 located under lugs 1129 and 1130, which support the entire weightof the vessel 1103. The vibrating hopper 1015 is supported by a frame1131, which is supported by a further frame 1132 mounted on a skid 1133.An expansion or isolation joint (not shown) or a rubber skirt 1134 isarranged between the vibrating hopper 1015 and the inlet valve 1101,which isolates the vibrating hopper 1015 from the vessel 1103. A valve1135 (e.g. a gate valve) is located at the bottom of the hopper 1015 andabove the rubber skirt 1134 to isolate the weight of cuttings in thehopper 1015 from the vessel 1103. The valve 1135 is closed after apredetermined time period, during which a measurement is taken by theload cell 1127, which gives an indication as to how full the vessel 1103is. The valve 1135 is then opened. The inlet valve 1101 is fully openduring a fill cycle and is closed during a convey cycle. A further loadcell 1136 is located between the hopper and the further frame 1132 sothat the weight of cuttings in the hopper 1015 can be monitored toensure that the hopper 1015 is not overfilled.

In one aspect, the conveying line 1014 leads to an inlet of the storagevessels 1019. The storage vessels are arranged on the offshore rig or ifit is a land based rig, near the rig, for example within 300 metersalthough may be up to three or four kilometers away.

FIG. 29A shows an alternative flow scheme and apparatus for the line1109 a shown in FIG. 29 (or for any similar flow line or conduit in anysystem according to the present invention disclosed herein). Toaccommodate both wet and dry cuttings and to provide adjustment fordifferent cuttings, the position of selectively operable valves 1151 and1152 determines whether air from the line 1109 a flows through anorifice 1153 or through an orifice 1154. The open area of the orifice1153 is greater than the open area of the orifice 1154. When the systemis processing dry cuttings, i.e., when greater air velocity is needed tomaintain material in suspension in an air flow, the valve 1152 is closedand air flows through the line 1150, through the open valve 1151,through the orifice 1153 and to the inlet 1109 so that an appropriateair flow to move dry material is achieved (e.g. at between a pressure of1 to 1.5 bar). When the system is processing wet cuttings, i.e. whenlesser air velocity is needed to achieve solids accumulation and flow inthe exit lines, the valve 1151 is closed and air flows through the line1109 a, through the open valve 1152, through the orifice 1154, and tothe inlet 1109 so that an appropriate air flow for wet material isachieved (e.g. at a pressure of about 4 bar). The system as shown inFIG. 29A may be used in the system of FIG. 29 (and in other systemsdescribed below) and, as shown in FIG. 29A, the line 1115 a and itsassociated apparatus, valve, inlet, etc. is optional for systemsaccording to the present invention. In one particular aspect, to conveymaterial through the system, the valves 1101, 1126, and 1124 b areclosed; the valves 1124 a and 1106 c are open (to equalize pressureacross the screw 1107); and the screw 1107 is turned at a selected speed(e.g. appropriate for wet cuttings or dried cuttings) to move cuttingsmaterial to the reducer 1108. The control system PD which may beconnected to each sensor, operable apparatus, motor, and item in thesystem (which may be a PID control system or a PLC system) is programmedto handle wet or dry cuttings and to control all valves, including thevalves 1151, 1152 when present.

In one aspect, following the fill sequence a convey sequence isinitialized whereby inlet valve 1101, vent valve 1126 and the flush airvalve 1124 b are closed, outlet valve 1114, conveying air valve 1124 aand pressure equalization valve 1106 are opened. This facilitates airflow from the compressor through the discharge pipework 1014. Thepressure attained by this air is a function of the pipe length,configuration, bore, internal surface finish and air flowrate. Anorifice 1154 is sized such that the volummetric flow rate of air is suchthat a predetermined air velocity is achieved suitable for the transferof drill cuttings. Typically this velocity would be around 20 meters persecond for a dried drill cutting i.e. powder/granular compositionwhereby the mode of transfer within the line 1014 is termed dilutephase. Dilute phase transfer is such that the material is transferredthrough the pipe at a velocity above that of the saltation velocity ofthe material. Air velocity at around 10 meters per second is utilizedwhen transferring drill cuttings as taken direct from a shale shaker,from the shale shaker the drill cuttings will have a drill mudconstituent thus resulting in a cohesive agglomerative substance forwhich the optimal transfer regime within the line 1014 is known to bedense phase. Dense phase describes the flow of material through the pipeas being set off in waves/slugs. Dilute phase transfer may be achievedat a lower pressure, in one aspect, around 1.5 Bar compared to densephase which, in one aspect, utilizes 4 Bar. As such the appropriatepressure setting is generated by the air conveyor by introducingmaterial into the line 1014 at the appropriate rate. The cuttings arecarried/suspended in the airflow thus conveying in a uniformly dispersedphase during lean phase transfer. During dense phase the cuttings createa bed on the bottom of the pipe and as further material is added intothe pipe a critical volume occurs whereby the cuttings spontaneouslycreate a moving layer or wave/slug of cuttings. On startup thecompressed air flows through the conveying air valve 1124 and, in oneaspect, a pressure drop across the transfer line 1014 of around 0.3 Baris achieved, i.e. this is the pressure generated by the compressor tofacilitate the appropriate flow rate of air through the pipe. Themetering screw 1107 is then rotated in order to feed the cuttings intothe transfer line 1014; the addition of cuttings into this transfer linethen generates a back pressure which the control system can use as thebasis for determining the rotational speed of the metering screw 1107.In one aspect the PLC based control system utilizes a standard PID(proportional integral and derivative) control loop based on a set pointof either 1.5 Bar or 4 Bar depending on the cuttings being transported.As the pressure equalization valve 1106 is open, this facilitates anypressure generated at the transfer line 1014 to be equalized into thehopper 1103 which nullifies any adverse pressure gradient that mayeffect the performance of the metering screw 1107. An orifice is locatedwithin the pipe connection 1106 in order that the air flow into thehopper 1103 is minimized. This conveying cycle may be terminatedmanually, automatically via a timer, via a loss in weight system oralternatively based upon pressure feedback; i.e., it is understood thatif the air pressure generated at line 1014 approaches that of the emptyline pressure drop and the metering screw 1107 is rotating over aperiod, then it is known that the hopper 1103 is then empty and thus thetransfer cycle should be stopped. In one aspect, the convey stopprocedure includes: closing of the pressure equalization valve 1106 c,the conveying air valve 1124 a and outlet valve 1114; opening of theflush air valve 1124 b to further purge the transfer line 1014 until thepressure drop achieved approaches that of an empty pipe for a nominaltime period of around one minute. At the same time as the flush airvalve 1124 b is opened, the vent valve 1126 is opened in order to ensurethat no pressure is contained within hopper 1103. Following this, theinlet valve 1101 is opened in order to accept into hopper 1103 a newcharge of cuttings from hopper 1015. In this state, the vibratory motor1105 a is activated in order to assist the transfer of charge.

In certain particular aspects the valves 1124 a and 1124 b may bestandard butterfly valves.

Referring to FIGS. 32 and 33, the storage vessels 1019 include agenerally cylindrical vessel 1202 of circular cross section. The vessel,in one aspect, has an internal capacity of approximately 13.5 cubicmeters. The vessel 1202 has a substantially circular planar base 1203and a domed cap 1204. The planar base 1203 and the domed cap 1204 may beformed integrally or be welded to the wall of the vessel 1202. Thevessel 1202 may be made of steel of the type defined by British Standard1501 224-49B and is designed, in certain aspects, to withstand a workingpressure of between 1 and 20 Bar, preferably 7 Bar. The domed cap 1204has an air inlet 1205, having a 52 mm (two inch) diameter air supplyhose 1206 attached thereto. The domed cap 1204 is also provided with acuttings inlet pipe 1207 provided with a valve 1208, such as a flapvalve or butterfly valve which may be operable remotely using a steppermotor. The cuttings inlet 1201 has, in certain aspects, an internaldiameter of 125 mm (5 inches). The planar base 1203 has a generallyrectangular opening 1209 arranged along the diameter of the planar base1204. A tube 1210 has a rectangular opening corresponding to and fixedto the perimeter of the opening 1209 in the planar base 1204 to form apressure tight seal. The tube 1210 may be welded or otherwise formedwith the planar base 1203. The tube 1210 houses a screw conveyor 1211driven by a variable speed hydraulic motor 1212 through a gear box 1213.The motor 1212 may alternatively be electric, petrol, pneumatic orotherwise powered motor.

The screw conveyor 1211 is, in certain aspects, a ribbon screw having noshaft or, as shown in FIG. 32, is a shaft 1214 and a helical blade 1215.The helical blade 1215, in one aspect, has a diameter of between 150 mmand 600 mm (6 and 24 inches), and may have a diameter of about 300 mm(twelve inches). The pitch of the screw may be constant or may reduce inpitch away from the discharge end. The shaft 1214 has a first endcoupled to the variable speed hydraulic motor 1212 and a second endrotatably arranged in a bearing (not shown) in a discharge end of thetube 1210. The helical blade 1215 extends along substantially the entirediameter of the planar base 1203 and extends into a portion of a flangedpipe stub 1216. A discharge set up is very similar to the arrangementfor the dosing apparatus 1000 in that it has a reducer 1217 providedwith a air inlet 1218 in an outer wall 1219. The air inlet 1218 is influid communication with an annulus 1220 formed by the flanged pipe stub1216 and the outer wall 1219. The flanged pipe stub 1216 has, in oneaspect, an inner diameter substantially equal to the inner diameter ofthe tube 1210 for the screw 1211, which is about 30 cm (twelve inches).The annulus 1220 has an opening 1221 formed by the end of the pipe stub1216 and a converging wall 1222 of the reducer 1217. A valve 1223 islocated at the converged end of the converging wall 1222. The innerdiameter of the converged end of the converging wall 1222, in oneaspect, is 20 cm (eight inches) in diameter. An air inlet 1225 isprovided in an outer wall 1226 having a substantially concentric flangedpipe stub 1227 forming an annulus 1228 therebetween. The flanged pipestub 1227 has, in one aspect, an inner diameter substantially equal tothe inner diameter of the converged end of the converging wall 1222. Theannulus 1228 has an opening 1229 formed by a converged end of the pipestub 1227 and a converging part 1230 of outer wall 1226. The innerdiameter of the end of the converged outer wall, in one aspect, is 125cm (five inches) which is connected to a conveying line which has aninternal diameter of 125 mm (5 inches) and may be a hose or rigid pipe.The cuttings outlet 1231 has an internal diameter of 125 mm (5 inches)and is attached to a cuttings conveying line (not shown) of the sameinternal diameter, which may be a flexible hose or a rigid pipe. A valveapparatus 1250 controls flow to the inlet 1218 and a valve apparatus1251 controls flow to the inlet 1225. This system can operate as asystem utilizing the apparatuses in FIG. 29 and in FIG. 29A and thesevalves can act as do the valves 1124 a, b, FIG. 29.

A sliding frame 1232 is arranged inside the vessel 1202 on the planarbase 1203 about opening 1209. The sliding frame 1232 has two symmetricalcurved members 1233 and 1234 forming an eye shape which is has a centralmember 1235 passing through the center of the planar base 1203 andarranged perpendicular to the opening 1209 and in line with ahydraulically actuated piston and cylinder 1236 is joined at one end tothe wall or planar base 1203 of the vessel 1202 and the other to thecenter of the central member 1235 of the sliding frame 1232, to inducemovement of the sliding frame 1232 over the planar base 1203 backwardsand forwards as indicated by the arrow within the confines of the vessel1202. The curvature of the two symmetrical curved members 1233 and 1234is the same or slightly less than the curvature of the perimeter of theplanar base 1203. The outer edges 1237 a and 1237 b of the twosymmetrical curved sections 1233 and 1234 are chamfered, whereas theinternal edges 1238 and 1239 facing the opening 1209 are at right anglesto the plane of the planar base 1203. The curved members 1233 and 1234have flat bottoms. The angle of the chamfer is, in certain aspects,between 45 and 20 degrees from the flat bottom.

The curved members 1233 and 1234 may have various profiles to accomplishthe function of sliding underneath the drill cuttings when moving awayfrom the opening 1209 and acting as a scoop to scoop the drill cuttingsinto the opening 209 for discharge.

The storage vessel 1019 is, optionally, attached to a skid 1240 tofacilitate transport of the storage vessel on trucks, lorries, supplyboats, train cars and on offshore and onshore rigs. The height of thestorage vessel when mounted on the skid is, in one aspect, 3.26 m, thelength of the skid is 3.95 m and the width of the skid is 2.9 m.

A pressure relief valve 1241 is provided in the pressure vessel 1202,which is set to between 10% and 20% above the normal working pressure ofup to 7 Bar. A hatch (not shown) is also provided in the wall of thepressure vessel 1202 to allow access for inspection, servicing andcleaning.

In use, the storage vessel 1019 is vented to atmosphere, either using avalve or by disconnecting the air supply line 1206 from the air inlet1205. Doses of drill cuttings enter the storage vessel 1019 through thefeed line 1014 from the apparatus 1000 and gradually fill the storagevessel 1019. The storage vessel 1019 can store up to preferably, twelvecubic meters of drill cuttings, but may be sized to store between fiveand 20 cubic meters. Vessel capacity is indicated via load cells todetermine mass capacity or a level sensor is used to do this. Once thestorage tank 1019 is full or near full, a valve (not shown) in the feedline is operated to divert the doses of drill cuttings to anotherstorage vessel, like the vessel 1010. Alternatively, the feed line isdisconnected from cuttings inlet 1201 and connected to the cuttingsinlet on a further storage vessel 1019.

At a convenient time when the supply boat or vehicle to transport thedrill cuttings is in close proximity to the bank 1010 of storage vessels1019, for example when the supply boat is moored to or within three orfour hundred meters of the offshore rig, one end of a flexible hose 1009is connected to one of the storage vessels 1019. The other end of theflexible hose is connected to at least one storage vessel 1013 in a bank1010 of storage vessels 1013 on the supply ship. The storage vessels1013 are, in one aspect, of the type described with reference to FIGS.28 and 29 herein. Floatation collars FC may be provided on the flexiblehose to inhibit the hose from sinking into the sea. Air enters the inlet1205 in the pressure vessel 1202 and through inlet 1218 to equalize thepressure across the screw 1211. Valve 1223 is opened and air inlet 1225is closed. The screw 1211 is then rotated by activating motor 1212through gear box 213. The drill cuttings 1249 are dosed by the screw1211 into reducer 1217 and blown through the valve 1223 and intoconveying line 1009. A pressure monitoring device 1250 monitors thepressure at the inlet 1218. In one aspect, a PID control systemmaintains the pressure at the inlet 1218 at between 3.5 to 4 bar (densephase) or to ⅕ bar (lean phase) by altering the speed of rotation of thescrew 1211 for conveying the drill cuttings material. If the pressurereading is too high, the speed of rotation of the screw 1211 will bedecreased; if the pressure is too low, the speed of rotation of thescrew 1211 will be increased. The drill cuttings are conveyed along theconveying line 1009 in slugs. In certain aspects, the slugs will bebetween 0.5 m and 10 m long. The hydraulic piston and cylinder 1236 isactivated to move the sliding frame 1232 backwards and forwards tofacilitate movement of the drill cuttings into opening 1209. Thechamfered edges on the sides of the members 1236, 1237 of the slidingframe 1232 ensure that upon movement away from the opening 1209 thecomponents of the sliding frame slide under the drill cuttings and uponmovement towards the opening 1209, the opposed right angle or scoopprofile surfaces pull the drill cuttings towards the opening 1209. Thedrill cuttings move through opening 1209 into the screw conveyor. Thusthe first drill cuttings to enter the pressure vessel 1202, are thefirst drill cuttings to be removed from the pressure vessel 1202. Oncethe storage vessel 1200 is empty valve 1223 is closed, the pressurizedair supply through inlets 1205 and 1218 is stopped and the pressurizedair is diverted through inlet 1225 to maintain pressure in the conveyingline 1009. Air pressure in the pressure vessel 1202 is allowed to ventto atmospheric pressure through vent 1241 or by a diverter valve (notshown).

In one aspect, the pressurized air supply on a rig is set at 7 bar.

FIG. 34 shows an alternative form of reducer 1308 to the reducersdescribed above. Reducer 1308 has a lower wall collinear with the lowerpart of the outer wall 1310 and a portion which slopes from the top ofthe outer wall 1310 to the top of the valve 1314, such that the centerof the valve 1314 is off-center from the axis of the screw 1307. Theopening to the screw 1307 may be circular (see FIG. 34D), oval, square(see FIG. 34A), rectangular (see FIG. 34B) or any polygon shape (e.g.see FIG. 34C) and the reducer may reduce to a smaller opening which mayalso be circular, oval, square or any polygon shape the diameter of thevalve 1314. The floor of the reducer 1308 is substantially horizontal,which facilitates the conveying of liquid along the conveying line. Likenumerals in FIGS. 34 and 35 indicate like parts as in FIG. 29.

FIG. 35 shows an alternative position for a valve 1314 a (like the valve1314, FIG. 34). The valve 1314 a is located at the exit of the screw,which may be substantially the same diameter as the screw 1107 and thereducer 1108 may be located external the valve 1314 a. Optionally, thereis a gap 1307 a between the conveyor and the valve 1314 a.

In one aspect, when a system according to the present invention, e.g. asshown in FIGS. 28 and 36, deals with relatively dry cuttings, thepressure in the dosing apparatus (e.g. in the dosing apparatus 1000,FIG. 29 or apparatus 1330, FIG. 36) and in storage vessels (e.g. astorage vessel 1019, FIG. 28) can be maintained at a level less thanthat used in storage vessels of systems that process relatively wetdrilling cuttings material; e.g., in certain aspects a pressure of 3.5to 4 bars is used with the relatively wet material whereas a pressure of1.2 to 2 bars is used for the relatively dry material. Also, with therelatively dry material, the speed of air and material in conveyinglines and conduits can be greater than the speed of air and relativelywet material. In certain aspects, therefore, air inlet orifices can belarger when processing relatively dry material.

FIG. 36 shows a system 1320 according to the present invention forconveying drill cuttings from shale shakers 1322 (shown schematically)which flow in a conveyor 1324 (any ditch herein may have a conveyor) tocuttings dryer apparatus, e.g. one, two, three or more dryers. Anysuitable dryer apparatus or system may be used. As shown in FIG. 36 twovortex dryers 1326 (any as described or referred to herein and, in oneaspect, as described in Great Britain Patent No. 2, 297,702 A) receivethe drilling cuttings material and the material flows from the dryers1326 to a dosing apparatus 1330 (like any described herein, e.g. as inFIGS. 29, 29A, and/or 32). Material exits the apparatus 1330 in aconduit 1334.

The dryers 1326 remove moisture from the material and, in certainaspects, remove a substantial amount of moisture. In certain aspects,the total moisture content by weight of the material is reduced to about3% and, in certain particular aspects, it is reduced to between 1% and3% by weight. Such relatively dry material is relatively free flowing,is not a paste, is not a free flowing paste, and is not a non-freeflowing paste. Thus, in certain aspects, e.g. speeds of e.g. 30 m/secdry are achieved with the relatively dry material while speeds of e.g.10-12 m/sec wet are achieved with the relatively wet material.

FIGS. 37A-37C show alternative flow paths and circuits of a systemaccording to the present invention as in FIGS. 29 and 29A and likenumerals indicate like parts.

The system as shown in FIG. 37B has a valve 1124 r (like the valve 1124b) downstream of an orifice 1154 r (like the orifice 1154). A valve 1124s is downstream of the orifice 1154. The conveying air valve 1124 a isdownstream of an orifice 1154 t. As shown in FIG. 37B, and as is truefor the other embodiments with an upstream connection 1109 and adownstream connection 1115, air is supplied to the upstream connection1109 when the hopper 1103 is being emptied in a material conveyance modeand the pressure equalization valve 1106 c is open so that the pressureacross the metering screw is equalized (and the valve 1106 c is closedwhen filling the hopper 1103 since the hopper 1103 is then open toatmosphere via the valve 1101). Air is supplied to the downstreamconnection 1115 while the hopper 1103 is being filled so that conveyancecan continue (or to blow through the discharge pipe for cleaning). Bychoosing which valves (1124 a, 1124 b, 1124 r, 1124 s) to open or closea particular line with a particular orifice is chosen for particularmaterial (wet or dry).

The present invention, in certain aspects, provides a system forconveying material from a vessel, the system having a vessel forreceiving material to be conveyed; a first conduit for conveying air; asecond conduit for receiving air from the first conduit and forconveying air into the vessel; a metering screw for receiving materialfrom the vessel and for moving the material from the vessel; a dischargeline for receiving the material from the metering screw, the dischargeline having an exit end; pressure sensor apparatus for sensing pressurein the discharge line; and control apparatus for automaticallycontrolling the metering screw in response to a pressure sensed by thepressure sensor apparatus. Such a system may include one or some (in anypossible combination) of the following: an outlet valve for selectivelyopening and closing the discharge line, a third conduit for receivingair from the first conduit and for conveying said air to the dischargeline, the third conduit between the metering screw and the outlet valve,and a fourth conduit for receiving air from the first conduit and forconveying air to the discharge line, the fourth conduit between theoutlet valve and the exit end of the discharge line; a first valve forselectively controlling flow in the first conduit, a second valve forselectively controlling flow in the second conduit, and a third valvefor selectively controlling flow in the third conduit; the controlapparatus including selection apparatus for selecting a first air flowor a second air flow to flow to the third conduit, flow apparatus forflowing the first air flow or the second air flow into the third conduitfor flow into the discharge line, and the first air flow at a velocitydifferent from a velocity of the second air flow; wherein the controlapparatus includes a first line with a first orifice member, a secondline with a second orifice member, the first line having flow openingarea less than an opening area of the second line so that air at avelocity greater than a velocity of air in the first line is flowablefrom the second line, and valve apparatus for controlling flow in thefirst line and the second line so that flow from either line may beselected; the flow opening area of the first line is sized forfacilitating the flow of wet material through the discharge line, andthe flow opening area of the second line is sized for facilitating theflow of dry material through the discharge line; with the first andthird valves open, air pressure equalized across the metering screw; afirst reducer in the discharge line having a first diameter at a firstend and a second diameter at a second end, the diameter of the firstreducer gradually decreasing from the first end to the second end, thefirst end closer to the vessel than the second end; wherein the materialis drilling cuttings material; and/or wherein the drilling cuttingsmaterial is from the group consisting of wet cuttings material and drycuttings material; and/or movement apparatus, the movement apparatuscomprising a movement member within the vessel and movable adjacent anopening of the vessel to facilitate passage of the material to themetering screw; wherein the movement member comprises a frame comprisinga control shaft connected to a generally circular shaped outer perimeterportion and at least one cross-member; wherein the vessel has two sideswhich slope toward each other; wherein the vessel has a conical hopperportion, wherein the conical hopper portion has a cone angle and forms alower section of the vessel and the cone angle is below a critical valuerequired to achieve mass flow of the drilling cuttings material.

The present invention, in certain aspects, provides a system forconveying material from a vessel, the system having a vessel forreceiving material to be conveyed; a first conduit for conveying air; asecond conduit for receiving air from the first conduit and forconveying air into the vessel; a metering screw for receiving materialfrom the vessel and for moving the material from the vessel; a dischargeline for receiving the material from the metering screw, the dischargeline having an exit end; pressure sensor apparatus for sensing pressurein the discharge line; control apparatus for automatically controllingthe metering screw in response to a pressure sensed by the pressuresensor apparatus; an outlet valve for selectively opening and closingthe discharge line; a third conduit for receiving air from the firstconduit and for conveying said air to the discharge line, the thirdconduit between the metering screw and the outlet valve; a fourthconduit for receiving air from the first conduit and for conveying airto the discharge line, the fourth conduit between the outlet valve andthe exit end of the discharge line; a first valve for selectivelycontrolling flow in the first conduit; a second valve for selectivelycontrolling flow in the second conduit; a third valve for selectivelycontrolling flow in the third conduit; the control apparatus includingselection apparatus for selecting a first air flow or a second air flowto flow to the third conduit; flow apparatus for flowing the first airflow or the second air flow into the third conduit; the first air flowat a velocity different from a velocity of the second air flow; whereinthe control apparatus includes a first line with a first orifice member,a second line with a second orifice member, the first line having flowopening area less than an opening area of the second line so that air ata velocity greater than a velocity of air in the first line is flowablefrom the second line; and valve apparatus for controlling flow in thefirst line and the second line so that flow from either line may beselected; the flow opening area of the first line is sized forfacilitating the flow of wet material through the discharge line; theflow opening area of the second line is sized for facilitating the flowof dry material through the discharge line; with the first and thirdvalves open, air pressure equalized across the metering screw; andwherein the material is drilling cuttings material.

The present invention, in certain aspects, provides a method for movingdrilling cuttings material from a system according to the presentinvention, the method including: introducing drilling cuttings materialinto a vessel of the system; sensing pressure in a discharge line fromthe vessel with a pressure sensor apparatus, and controlling a meteringscrew which meters material to the discharge line with a controlapparatus. Such a method may include one or some (in any possiblecombination) of the following: reducing rotation speed of the meteringscrew in response to sensed pressure; increasing rotation speed of themetering screw in response to sensed pressure; and/or facilitating theflow of material through the discharge line with a first or second airflow as described above.

In conclusion, therefore, it is seen that the present invention and theembodiments disclosed herein and those covered by the appended claimsare well adapted to carry out the objectives and obtain the ends setforth. Certain changes can be made in the subject matter withoutdeparting from the spirit and the scope of this invention. It isrealized that changes are possible within the scope of this inventionand it is further intended that each element or step recited in any ofthe following claims is to be understood as referring to all equivalentelements or steps. The following claims are intended to cover theinvention as broadly as legally possible in whatever form it may beutilized. The invention claimed herein is new and novel in accordancewith 35 U.S.C. § 102 and satisfies the conditions for patentability in §102. The invention claimed herein is not obvious in accordance with 35U.S.C. § 103 and satisfies the conditions for patentability in § 103.This specification and the claims that follow are in accordance with allof the requirements of 35 U.S.C. § 112. The inventor may rely on theDoctrine of Equivalents to determine and assess the scope of theirinvention and of the claims that follow as they may pertain to apparatusnot materially departing from, but outside of, the literal scope of theinvention as set forth in the following claims. Any patent or patentapplication referred to herein is incorporated fully herein for allpurposes.

1. A system for conveying material from a vessel, the system comprising a vessel for receiving material to be conveyed, a first conduit for conveying air, a second conduit for receiving air from the first conduit and for conveying air into the vessel, a metering screw for receiving material from the vessel and for moving the material from the vessel, a discharge line for receiving the material from the metering screw, the discharge line having an exit end, pressure sensor apparatus for sensing pressure in the discharge line, control apparatus for automatically controlling the metering screw in response to a pressure sensed by the pressure sensor apparatus, an outlet valve for selectively opening and closing the discharge line, a third conduit for receiving air from the first conduit and for conveying said air to the discharge line, the third conduit between the metering screw and the outlet valve, a fourth conduit for receiving air from the first conduit and for conveying air to the discharge line, the fourth conduit between the outlet valve and the exit end of the discharge line, a first valve for selectively controlling flow in the first conduit, a second valve for selectively controlling flow in the second conduit, a third valve for selectively controlling flow in the third conduit, the control apparatus including selection apparatus for selecting a first air flow or a second air flow to flow to the third conduit, flow apparatus for flowing the first air flow or the second air flow into the third conduit, the first air flow at a velocity different from a velocity of the second air flow, wherein the control apparatus includes a first line with a first orifice member, a second line with a second orifice member, the first line having flow opening area lass than an opening area of the second line so that air at a velocity greater than a velocity of air in the first line is flowable from the second line, and valve apparatus for controlling flow in the first line and the second line so that flow from either line may be selected, the flow opening area of the first line is sized for facilitating the flow of wet material through the discharge line, the flow opening area of the second line is sized for facilitating the flow of dry material through the discharge line, with the first and third valves open, air pressure equalized across the metering screw, and wherein the material is drilling cuttings material.
 2. The system of claim 1 further comprising movement apparatus, the movement apparatus comprising a movement member within the vessel and movable adjacent an opening of the vessel to facilitate passage of the material to the metering screw.
 3. The system of claim 2 wherein the movement member comprises a frame comprising a control shaft connected to a generally circular shaped outer perimeter portion and at least one cross-member.
 4. The system of claim 2 wherein the vessel has two sides which slope toward each other.
 5. The system of claim 2 wherein the vessel has a conical hopper portion, wherein the conical hopper portion has a cone angle and forms a lower section of the vessel and the cone angle is below a critical value required to achieve mass flow of the drilling cuttings material.
 6. A system for conveying material from a vessel, the system comprising a vessel for receiving material to be conveyed, a first conduit for conveying air, a second conduit for receiving air from the first conduit and for conveying air into the vessel, a metering screw for receiving material from the vessel and for moving the material from the vessel, a discharge line for receiving the material from the metering screw, the discharge line having an exit end, pressure sensor apparatus for sensing pressure in the discharge line, control apparatus for automatically controlling the metering screw in response to a pressure sensed by the pressure sensor apparatus, an outlet valve for selectively opening and closing the discharge line, a third conduit for receiving air from the first conduit and for conveying said air to the discharge line, the third conduit between the metering screw and the outlet valve, and a fourth conduit for receiving air from the first conduit and for conveying air to the discharge line, the fourth conduit between the outlet valve and the exit end of the discharge line.
 7. The system of claim 6 further comprising a first valve for selectively controlling flow in the first conduit, a second valve for selectively controlling flow in the second conduit, and a third valve for selectively controlling flow in the third conduit.
 8. The system of claim 7 further comprising the control apparatus including selection apparatus for selecting a first air flow or a second air flow to flow to the third conduit, flow apparatus for flowing the first air flow or the second air flow into the third conduit for flow into the discharge line, and the first air flow at a velocity different from a velocity of the second air flow.
 9. The system of claim 8 wherein the control apparatus includes a first line with a first orifice member, a second line with a second orifice member, the first line having flow opening area less than an opening area of the second line so that air at a velocity greater than a velocity of air in the first line is flowable from the second line, and valve apparatus for controlling flow in the first line and the second line so that flow from either line may be selected.
 10. The system of claim 9 wherein the flow opening area of the first line is sized for facilitating the flow of wet material through the discharge line, and the flow opening area of the second line is sized for facilitating the flow of dry material through the discharge line.
 11. The system of claim 7 further comprising with the first and third valves open, air pressure equalized across the metering screw.
 12. The system of claim 6 further comprising a first reducer in the discharge line having a first diameter at a first end and a second diameter at a second end, the diameter of the first reducer gradually decreasing from the first end to the second end, the first end closer to the vessel than the second end.
 13. The system of claim 6 wherein the material is drilling cuttings material.
 14. The system of claim 13 wherein the drilling cuttings material is from the group consisting of wet cuttings material and dry cuttings material.
 15. A method for moving drilling cuttings material from a system, the system having a vessel for receiving material to be conveyed, a first conduit for conveying air, a second conduit for receiving air from the first conduit and for conveying air into the vessel, a metering screw for receiving material from the vessel and for moving the material from the vessel, a discharge line for receiving the material from the metering screw, the discharge line having an exit end, pressure sensor apparatus for sensing pressure in the discharge line, and control apparatus for automatically controlling the metering screw in response to a pressure sensed by the pressure sensor apparatus; the method comprising introducing drilling cuttings material into the vessel, sensing pressure in the discharge line with the pressure sensor apparatus, controlling the metering screw with the control apparatus, wherein the system comprises an outlet valve for selectively opening and closing the discharge line, a third conduit for receiving air from the first conduit and for conveying said air to the discharge line, the third conduit between the metering screw and the outlet valve, and a fourth conduit for receiving air from the first conduit and for conveying air to the discharge line, the fourth conduit between the outlet valve and the exit end of the discharge line, a first valve for selectively controlling flow in the first conduit, a second valve for selectively controlling flow in the second conduit, and a third valve for selectively controlling flow in the third conduit, the control apparatus including selection apparatus for selecting a first air flow or a second air flow to flow to the third conduit, flow apparatus for flowing the first air flow or the second air flow into the third conduit, and the first air flow at a velocity different from a velocity of the second air flow, wherein the control apparatus includes a first line with a first orifice member, a second line with a second orifice member, the first line having flow opening area less than an opening area of the second line so that air at a velocity greater than a velocity of air in the first line is flowable from the second liner and valve apparatus for controlling flow in the first line and the second line so that flow from either line may he selected, the method further comprising selecting the first air flow or the second air flow.
 16. The method of claim 15 wherein the flow opening area of the first line is sized for facilitating the flow of wet material through the discharge line, and the flow opening area of the second line is sized for facilitating the flow of dry material through the discharge line, the method further comprising facilitating the flow of material through the discharge line.
 17. The method of claim 15 further comprising reducing rotation speed of the metering screw in response to sensed pressure.
 18. The method of claim 15 further comprising increasing rotation speed of the metering screw in response to sensed pressure. 